U.S. patent application number 15/368110 was filed with the patent office on 2017-05-25 for high strength polyurethane foam compositions and methods.
The applicant listed for this patent is Saudi Aramco Technologies. Invention is credited to Scott D. Allen, Aisa Sendijarevic, Vahid Sendijarevic.
Application Number | 20170145147 15/368110 |
Document ID | / |
Family ID | 50685148 |
Filed Date | 2017-05-25 |
United States Patent
Application |
20170145147 |
Kind Code |
A1 |
Allen; Scott D. ; et
al. |
May 25, 2017 |
HIGH STRENGTH POLYURETHANE FOAM COMPOSITIONS AND METHODS
Abstract
Disclosed are high strength polyurethane foam compositions and
methods of making them. In one aspect, the inventive polyurethane
foams include strength enhancing additives comprising one or more
polycarbonate polyols derived from the copolymerization of CO.sub.2
and one or more epoxides. In one aspect, the inventive methods
include the step of substituting a portion of the polyether polyol
in the B-side of a foam formulation with one or more polycarbonate
polyols derived from the copolymerization of CO.sub.2 and one or
more epoxides.
Inventors: |
Allen; Scott D.; (Ithaca,
NY) ; Sendijarevic; Vahid; (Troy, MI) ;
Sendijarevic; Aisa; (Troy, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Saudi Aramco Technologies |
Dhahran |
|
SA |
|
|
Family ID: |
50685148 |
Appl. No.: |
15/368110 |
Filed: |
December 2, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14440903 |
May 6, 2015 |
9512259 |
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PCT/US13/68932 |
Nov 7, 2013 |
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15368110 |
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61758500 |
Jan 30, 2013 |
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61731723 |
Nov 30, 2012 |
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61723627 |
Nov 7, 2012 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C08G 18/7671 20130101;
C08G 18/14 20130101; C08G 18/44 20130101; C08G 18/3275 20130101;
C08G 2101/0016 20130101; C08G 18/7621 20130101; C08G 18/6607
20130101; C08G 2101/0008 20130101; C08G 18/4018 20130101; C08G
18/4009 20130101; C08G 18/7664 20130101; C08G 2101/0058 20130101;
C08G 18/72 20130101; C08G 2101/005 20130101; C08G 2101/0083
20130101 |
International
Class: |
C08G 18/44 20060101
C08G018/44; C08G 18/08 20060101 C08G018/08; C08G 18/76 20060101
C08G018/76 |
Claims
1-29. (canceled)
30. A method for increasing the strength of a polyurethane foam
composition, the foam composition comprising the reaction product
of a polyol component and a polyisocyanate component, the method
comprising the step of incorporating into the polyol component a
polycarbonate polyol derived from the copolymerization of one or
more epoxides and carbon dioxide, wherein the polycarbonate polyol
is added in a quantity from about 2 weight percent to about 50
weight percent, from about 5 weight percent to about 25 weight
percent, from about 2 weight percent to about 10 weight percent,
from about 10 weight percent to about 20 weight percent, from about
20 weight percent to about 30 weight percent, or from about 30
weight percent to about 50 weight percent of all polyols present in
the polyol component; wherein a tensile strength value measured by
ASTM D 3574-08 of the foam composition comprising the added
polycarbonate polyol is greater than the tensile strength value of
a corresponding foam composition formulated without the added
polycarbonate polyol.
31. The method of claim 30, wherein the polyol component comprises
one or more polyols selected from the group consisting of polyether
polyols, polyester polyols, aliphatic polyols, and mixtures of any
two or more of these.
32. The method of claim 31, wherein the polyol component
substantially comprises polyether polyol.
33. The method of claim 30, wherein the tensile strength value of
the foam composition comprising the added polycarbonate polyol is
at least 10%, at least 20%, at least 30%, at least 40%, at least
50%, or at least 100% greater than the tensile strength value of
the corresponding foam composition formulated without the added
polycarbonate polyol.
34. The method of claim 30, wherein the tensile strength values are
normalized for density of the foam compositions being compared.
35. The method of claim 30, wherein the foam compositions are
formulated such that the foam composition comprising the added
polycarbonate polyol and the corresponding foam composition
formulated without the added polycarbonate polyol have
substantially the same density.
36. The method of claim 30, wherein the foam composition comprises
flexible polyurethane foam, or wherein the foam composition
comprises viscoelastic polyurethane foam, or wherein the foam
composition comprises rigid polyurethane foam.
37. The method of claim 30, wherein the density measured according
to ASTM D3574 of the foam composition comprising the added
polycarbonate polyol is less than the density of the corresponding
foam composition formulated without the added polycarbonate polyol,
and wherein the tensile strength value measured according to ASTM
D3574-08 of the foam composition comprising the added polycarbonate
polyol is greater than the tensile strength value of the
corresponding foam composition formulated without the added
polycarbonate polyol.
38. The method of claim 37, wherein the density of the foam
composition comprising the added polycarbonate polyol is at least
10%, at least 20%, at least 30%, at least 40% or at least 50% less
than the density of the corresponding foam composition formulated
without the added polycarbonate polyol.
39. The method of claim 37, wherein the tensile strength value of
the foam composition comprising the added polycarbonate polyol is
at least 10%, at least 20%, at least 30%, at least 40% or at least
50% greater than the tensile strength value of the corresponding
foam composition formulated without the added polycarbonate
polyol.
40. The method of claim 30, wherein the polycarbonate polyol
contains a primary repeating unit having a structure: ##STR00144##
where R.sup.1, R.sup.2, R.sup.3, and R.sup.4 are, at each
occurrence in the polymer chain, independently selected from the
group consisting of --H, fluorine, an optionally substituted
C.sub.1-40 aliphatic group, an optionally substituted C.sub.1-20
heteroaliphatic group, and an optionally substituted aryl group,
where any two or more of R.sup.1, R.sup.2, R.sup.3, and R.sup.4 may
optionally be taken together with intervening atoms to form one or
more optionally substituted rings optionally containing one or more
heteroatoms.
41. The method of claim 40, wherein the polycarbonate polyol
contains a primary repeating unit having a structure:
##STR00145##
42. The method of claim 41, wherein R.sup.1 is, at each occurrence
in the polymer chain, independently --H, or --CH.sub.3.
43. The method of claim 40, wherein the polycarbonate polyol is
characterized in that it has an Mn between about 500 g/mol and
about 20,000 g/mol, between about 1,000 g/mol and about 5,000
g/mol, between about 1,000 g/mol and about 3,000 g/mol, or between
about 1,000 g/mol and about 3,000 g/mol, or an Mn of about 1,000
g/mol, about 1,200 g/mol, about 1,500 g/mol, about 2,000 g/mol,
about 2,500 g/mol or about 3,000 g/mol.
44. The method of claim 40, wherein the aliphatic polycarbonate
polyol is characterized in that more than 98%, more than 99%, or
more than 99.5% of the chain ends are groups reactive toward
isocyanate.
45. The method of claim 44, wherein the chain ends reactive toward
isocyanate comprise --OH groups.
46. A polyurethane foam composition comprising the reaction product
of a polyol component and a polyisocyanate component, wherein the
polyol component comprises a polycarbonate polyol derived from the
copolymerization of one or more epoxides and carbon dioxide,
wherein the polycarbonate polyol is present in a quantity from
about 2 weight percent to about 50 weight percent, from about 5
weight percent to about 25 weight percent, from about 2 weight
percent to about 10 weight percent, from about 10 weight percent to
about 20 weight percent, from about 20 weight percent to about 30
weight percent, or from about 30 weight percent to about 50 weight
percent of all polyols present in the polyol component and
characterized in that a tensile strength value measured according
to ASTM D 3574-08 of the foam composition comprising the added
polycarbonate polyol is greater than the tensile strength value of
a corresponding foam composition formulated without the added
polycarbonate polyol.
47. The polyurethane foam composition of claim 46, wherein the
polyol component comprises one or more polyols selected from the
group consisting of polyether polyols, polyester polyols, aliphatic
polyols, and mixtures of any two or more of these.
48. The polyurethane foam composition of claim 47, wherein the
polyol component substantially comprises polyether polyol.
49. The polyurethane foam composition of claim 46, wherein the
tensile strength value of the foam composition comprising the
polycarbonate polyol is at least 10%, at least 20%, at least 30%,
at least 40%, at least 50%, or at least 100% greater than the
tensile strength value of the corresponding foam composition
formulated without the added polycarbonate polyol.
50. The polyurethane foam composition of claim 49, wherein the
tensile strength values are normalized for density of the foam
compositions being compared.
51. The polyurethane foam composition of claim 49, wherein the foam
composition is formulated such that the foam composition comprising
the added polycarbonate polyol and the corresponding foam
composition formulated without the added polycarbonate polyol have
substantially the same density.
52. The polyurethane foam composition of claim 46, wherein the foam
composition comprises flexible polyurethane foam or wherein the
foam composition comprises viscoelastic polyurethane foam, or
wherein the foam composition comprises rigid polyurethane foam.
53. The polyurethane foam composition of claim 46, wherein the
density measured according to ASTM D3574-08 of the foam composition
comprising the polycarbonate polyol is less than the density of the
corresponding foam composition formulated without the polycarbonate
polyol.
54. The polyurethane foam composition of claim 53, wherein the
density of the foam comprising the polycarbonate polyol is at least
10%, at least 20%, at least 30%, at least 40% or at least 50% less
than the density of the corresponding foam composition formulated
without the added polycarbonate polyol.
55. The polyurethane foam composition of claim 53, wherein the
measured tensile strength value is at least 10%, at least 20%, at
least 30%, at least 40% or at least 50% greater than the tensile
strength value of the corresponding foam composition formulated
without the polycarbonate polyol.
56. The polyurethane foam composition of claim 46, wherein the
polycarbonate polyol contains a primary repeating unit having a
structure: ##STR00146## where R.sup.1, R.sup.2, R.sup.3, and
R.sup.4 are, at each occurrence in the polymer chain, independently
selected from the group consisting of --H, fluorine, an optionally
substituted C.sub.1-40 aliphatic group, an optionally substituted
C.sub.1-20 heteroaliphatic group, and an optionally substituted
aryl group, where any two or more of R.sup.1, R.sup.2, R.sup.3, and
R.sup.4 may optionally be taken together with intervening atoms to
form one or more optionally substituted rings optionally containing
one or more heteroatoms.
57. The polyurethane foam composition of claim 56, wherein the
polycarbonate polyol contains a primary repeating unit having a
structure: ##STR00147##
58. The polyurethane foam composition of claim 57, wherein R.sup.1
is, at each occurrence in the polymer chain, independently --H, or
--CH.sub.3.
59. The polyurethane foam composition of claim 56, wherein the
polycarbonate polyol is characterized in that it has an Mn between
about 500 g/mol and about 20,000 g/mol, between about 1,000 g/mol
and about 5,000 g/mol, or between about 1,000 g/mol and about 3,000
g/mol, or an Mn of about 1,000 g/mol, about 1,200 g/mol, about
1,500 g/mol, about 2,000 g/mol, about 2,500 g/mol or about 3,000
g/mol.
60. The polyurethane foam composition of claim 59, wherein the
polycarbonate polyol is characterized in that more than 98%, more
than 99%, or more than 99.5% of the chain ends are groups reactive
toward isocyanate.
61. The polyurethane foam composition of claim 60, wherein the
chain ends reactive toward isocyanate comprise --OH groups.
62. The method of claim 30, wherein the polycarbonate polyol is
characterized in that, on average in the composition, the
percentage of carbonate linkages is 85% or greater.
63. The method of claim 62, wherein the polycarbonate polyol is
characterized in that, on average in the composition, the
percentage of carbonate linkages is 90% or greater.
64. The method of claim 63, wherein the polycarbonate polyol is
characterized in that, on average in the composition, the
percentage of carbonate linkages is 95% or greater.
65. The method of claim 64, wherein the polycarbonate polyol is
characterized in that, on average in the composition, the
percentage of carbonate linkages is 98% or greater.
66. The method of claim 65, wherein the polycarbonate polyol is
characterized in that, on average in the composition, the
percentage of carbonate linkages is 99% or greater.
67. The polyurethane foam composition of claim 54, wherein the
polycarbonate polyol is characterized in that, on average in the
composition, the percentage of carbonate linkages is 85% or
greater.
68. The polyurethane foam composition of claim 67, wherein the
polycarbonate polyol is characterized in that, on average in the
composition, the percentage of carbonate linkages is 90% or
greater.
69. The polyurethane foam composition of claim 68, wherein the
polycarbonate polyol is characterized in that, on average in the
composition, the percentage of carbonate linkages is 95% or
greater.
70. The polyurethane foam composition of claim 69, wherein the
polycarbonate polyol is characterized in that, on average in the
composition, the percentage of carbonate linkages is 98% or
greater.
71. The polyurethane foam composition of claim 70, wherein the
polycarbonate polyol is characterized in that, on average in the
composition, the percentage of carbonate linkages is 99% or
greater.
Description
FIELD OF THE INVENTION
[0001] This invention pertains to the field of polyurethane foams.
More particularly, the invention pertains to additives and methods
for increasing the strength of polyurethane foams.
BACKGROUND OF THE INVENTION
[0002] Polyurethane foams derived from the reaction between
polyisocyanates and reactive polymers are widely used in
applications ranging from insulation and manufacture of furniture,
mattresses, consumer goods, construction materials, automotive
components and the like.
[0003] The cost of polyurethane foams has increased dramatically in
recent years due to increases in the cost of petroleum-based
feedstocks and the energy used to make them. At the same time, the
market demands are increasing for high performing materials that
are tough, have long service lifetimes and improved sustainability
profiles. Unfortunately, the current solutions to these problems
tend to increase one property at the expense of others.
[0004] For example, to make stronger foams, the density of the foam
is typically increased leading to a greater use of materials and
wasted energy required to transport materials. This is exacerbated
in transportation applications where the foam will be part of a
vehicle since the heavier foam will take a financial and
environmental toll through increased fuel usage throughout its
service lifetime. As such, compromises are often made wherein a
less durable or lower performing foam is selected based on cost or
weight considerations.
[0005] Similarly, efforts to make foam compositions more
sustainable by addition of biobased feedstocks have had mixed
results. Incorporation of soy or corn-based feedstocks in
polyurethane foam formulations often leads to sacrifice of
desirable properties and requires other changes to the formulations
to achieve acceptable performance-even with these concessions, it
has been difficult to incorporate more than about 10% of the
biobased material. The true sustainability of this approach is also
questionable especially when viewed as a whole, including the land
and water use and petroleum resources required to produce biobased
feedstocks--particularly if additional effort or petroleum-based
additives are required to compensate for negative effects these
materials have on the foam formulations.
[0006] It has previously been reported that polyurethane foams can
be formulated from polyols manufactured from CO.sub.2 (see for
example, co-owned patent applications WO 2010/028362 and
PCT/US12/047967). These foam compositions have improved carbon
footprints since up to 50% of the polyol's mass can be derived from
waste CO.sub.2 that would otherwise be released to the atmosphere.
In addition to sequestering a potential greenhouse gas, this
strategy allows the amount of fossil-fuel derived feedstock
utilized in manufacturing the polyol to be cut by up to 50/%.
[0007] Nonetheless, there remains a need for polyurethane foam
compositions with improved performance characteristics, and in
particular for formulations that have superior strength and
durability with equal or lesser weight than present materials.
SUMMARY OF THE INVENTION
[0008] As noted above, polyurethane foams incorporating epoxide
CO.sub.2 copolymers (aliphatic polycarbonate polyols) have been
described. Nonetheless, in certain aspects these foams presented
challenges. Foams formulated with epoxide CO.sub.2 copolymers as
the primary polyol component in the B-side can be difficult to
formulate (for example because of high viscosity). Furthermore, the
foams produced are sometimes friable or lacking in certain other
physical properties desirable in foams-especially in flexible
foams. In one aspect, the present invention emcompasses the
recognition that when used as an additive in the B-side of a
traditional foam formulation, the inclusion of epoxide CO.sub.2
copolymers does not have these negative effects, but instead their
presence unexpectedly increases desirable properties such as
strength, compression force deflection, solvent resistance and the
like.
[0009] Therefore, in one aspect, the present invention encompasses
high strength polyurethane foam compositions comprising the
reaction product of a polyol component and a polyisocyanate
component, wherein the polyol component comprises a blend of
polyols including from about 2 weight percent to about 50 weight of
a polycarbonate polyol derived from the copolymerization of one or
more epoxides and carbon dioxide. In certain embodiments, the
remainder of the polyol component comprises traditional polyether
or polyester polyols as are currently used in commercial foam
formulations. The foam compositions of the present invention
unexpectedly demonstrate improved physical strength including
higher compression force deflection and higher tear resistance than
foams formulated without the polycarbonate polyols. Importantly,
these improved foam compositions do not have higher density than
the initial foam, and other factors pertaining to comfort,
durability, inulation value and the like are not sacrificed.
[0010] In another aspect, the present invention encompasses methods
of strengthening polyurethane foam compositions. In certain
embodiments, the methods include a step of substituting from about
2 weight percent to about 50 weight percent of the polyol content
of a polyurethane foam formulation with a polycarbonate polyol
derived from the copolymerization of one or more epoxides and
carbon dioxide.
[0011] In another aspect, the present invention provides strength
enhancing additives for foam formulations. The inventive additives
comprise aliphatic polycarbonate polyols suitable for blending with
polyether or polyester polyols and characterized in that their
presence in a foam formulation increases one or more of the
compression force deflection value, the tear resistance or the
hysteresis of the final foam composition.
[0012] In another aspect, the present invention encompasses
articles made from high strength polyurethane foam compositions
resulting from adding polycarbonate polyols derived from the
copolymerization of one or more epoxides and carbon dioxide to the
foam formulation. Such articles include low density seating
materials for transportation applications, non seating foam
components for automobile manufacture, footwear foams, office
furniture, mattresses, sporting goods, construction materials and
consumer goods.
DEFINITIONS
[0013] Definitions of specific functional groups and chemical terms
are described in more detail below. For purposes of this invention,
the chemical elements are identified in accordance with the
Periodic Table of the Elements, CAS version, Handbook of Chemistry
and Physics, 75.sup.th Ed., inside cover, and specific functional
groups are generally defined as described therein. Additionally,
general principles of organic chemistry, as well as specific
functional moieties and reactivity, are described in Organic
Chemistry, Thomas Sorrell, University Science Books, Sausalito,
1999; Smith and March March's Advanced Organic Chemistry, 5.sup.th
Edition, John Wiley & Sons, Inc., New York, 2001; Larock,
Comprehensive Organic Transformations, VCH Publishers, Inc., New
York, 1989; Carruthers, Some Modern Methods of Organic Synthesis,
3.sup.rd Edition, Cambridge University Press, Cambridge, 1987; the
entire contents of each of which are incorporated herein by
reference.
[0014] Certain compounds of the present invention can comprise one
or more asymmetric centers, and thus can exist in various
stereoisomeric forms, e.g., enantiomers and/or diastereomers. Thus,
inventive compounds and compositions thereof may be in the form of
an individual enantiomer, diastereomer or geometric isomer, or may
be in the form of a mixture of stereoisomers. In certain
embodiments, the compounds of the invention are enantiopure
compounds. In certain embodiments, mixtures of enantiomers or
diastereomers are provided.
[0015] Furthermore, certain compounds, as described herein may have
one or more double bonds that can exist as either the Z or E
isomer, unless otherwise indicated. The invention additionally
encompasses the compounds as individual isomers substantially free
of other isomers and alternatively, as mixtures of various isomers,
e.g., racemic mixtures of enantiomers. In addition to the
above-mentioned compounds per se, this invention also encompasses
compositions comprising one or more compounds.
[0016] As used herein, the term "isomers" includes any and all
geometric isomers and stereoisomers. For example, "isomers" include
cis- and trans-isomers. E- and Z-isomers, R- and S-enantiomers,
diastereomers, (D)-isomers, (L)-isomers, racemic mixtures thereof,
and other mixtures thereof, as falling within the scope of the
invention. For instance, a stereoisomer may, in some embodiments,
be provided substantially free of one or more corresponding
stereoisomers, and may also be referred to as "stereochemically
enriched."
[0017] Where a particular enantiomer is preferred, it may, in some
embodiments be provided substantially free of the opposite
enantiomer, and may also be referred to as "optically enriched."
"Optically enriched," as used herein, means that the compound or
polymer is made up of a significantly greater proportion of one
enantiomer. In certain embodiments the compound is made up of at
least about 90% by weight of a preferred enantiomer. In other
embodiments the compound is made up of at least about 95%, 98%, or
99% by weight of a preferred enantiomer. Preferred enantiomers may
be isolated from racemic mixtures by any method known to those
skilled in the art, including chiral high pressure liquid
chromatography (HPLC) and the formation and crystallization of
chiral salts or prepared by asymmetric syntheses. See, for example,
Jacques, et al., Enantiomers, Racemates and Resolutions (Wiley
Interscience, New York, 1981); Wilen, S. H., et al., Tetrahedron
33:2725 (1977); Eliel, E. L. Stereochemistry of Carbon Compounds
(McGraw-Hill, N Y, 1962); Wilen, S. H. Tables of Resolving Agents
and Optical Resolutions p. 268 (E. L. Eliel, Ed., Univ. of Notre
Dame Press, Notre Dame, Ind. 1972).
[0018] The term "epoxide", as used herein, refers to a substituted
or unsubstituted oxirane. Such substituted oxiranes include
monosubstituted oxiranes, disubstituted oxiranes, trisubstituted
oxiranes, and tetrasubstituted oxiranes. Such epoxides may be
further optionally substituted as defined herein. In certain
embodiments, epoxides comprise a single oxirane moiety. In certain
embodiments, epoxides comprise two or more oxirane moieties.
[0019] The term "polymer", as used herein, refers to a molecule of
high relative molecular mass, the structure of which comprises the
multiple repetition of units derived, actually or conceptually,
from molecules of low relative molecular mass. In certain
embodiments, a polymer is comprised of substantially alternating
units derived from CO.sub.2 and an epoxide (e.g., poly(ethylene
carbonate). In certain embodiments, a polymer of the present
invention is a copolymer, terpolymer, heteropolymer, block
copolymer, or tapered heteropolymer incorporating two or more
different epoxide monomers. With respect to the structural
depiction of such higher polymers, the convention of showing
enchainment of different monomer units separated by a slash may be
used herein
##STR00001##
These structures are to be interpreted to encompass copolymers
incorporating any ratio of the different monomer units depicted
unless otherwise specified. This depiction is also meant to
represent random, tapered, block copolymers, and combinations of
any two or more of these and all of these are implied unless
otherwise specified.
[0020] The terms "halo" and "halogen" as used herein refer to an
atom selected from fluorine (fluoro, --F), chlorine (chloro, --Cl),
bromine (bromo, --Br), and iodine (iodo, --I).
[0021] The term "aliphatic" or "aliphatic group", as used herein,
denotes a hydrocarbon moiety that may be straight-chain (i.e.,
unbranched), branched, or cyclic (including fused, bridging, and
spiro-fused polycyclic) and may be completely saturated or may
contain one or more units of unsaturation, but which is not
aromatic. Unless otherwise specified, aliphatic groups contain 1-40
carbon atoms. In certain embodiments, aliphatic groups contain 1-20
carbon atoms. In certain embodiments, aliphatic groups contain 3-20
carbon atoms. In certain embodiments, aliphatic groups contain 1-12
carbon atoms. In certain embodiments, aliphatic groups contain 1-8
carbon atoms. In certain embodiments, aliphatic groups contain 1-6
carbon atoms. In some embodiments, aliphatic groups contain 1-5
carbon atoms, in some embodiments, aliphatic groups contain 1-4
carbon atoms, in some embodiments aliphatic groups contain 1-3
carbon atoms, and in some embodiments aliphatic groups contain 1 or
2 carbon atoms. Suitable aliphatic groups include, but are not
limited to, linear or branched, alkyl, alkenyl, and alkynyl groups,
and hybrids thereof such as (cycloalkyl)alkyl, (cycloalkenyl)alkyl
or (cycloalkyl)alkenyl.
[0022] The term "heteroaliphatic," as used herein, refers to
aliphatic groups wherein one or more carbon atoms are independently
replaced by one or more atoms selected from the group consisting of
oxygen, sulfur, nitrogen, or phosphorus. In certain embodiments,
one to six carbon atoms are independently replaced by one or more
of oxygen, sulfur, nitrogen, or phosphorus. Heteroaliphatic groups
may be substituted or unsubstituted, branched or unbranched, cyclic
or acyclic, and include saturated, unsaturated or partially
unsaturated groups.
[0023] As used herein, the term "bivalent C.sub.1-8 (or C.sub.1-3)
saturated or unsaturated, straight or branched, hydrocarbon chain",
refers to bivalent alkyl, alkenyl, and alkynyl, chains that are
straight or branched as defined herein.
[0024] The term "unsaturated", as used herein, means that a moiety
has one or more double or triple bonds.
[0025] The terms "cycloaliphatic", "carbocycle", or "carbocyclic",
used alone or as part of a larger moiety, refer to a saturated or
partially unsaturated cyclic aliphatic monocyclic or polycyclic
ring systems, as described herein, having from 3 to 12 members,
wherein the aliphatic ring system is optionally substituted as
defined above and described herein. Cycloaliphatic groups include,
without limitation, cyclopropyl, cyclobutyl, cyclopentyl,
cyclopentenyl, cyclohexyl, cyclohexenyl, cycloheptyl,
cycloheptenyl, cyclooctyl, cyclooctenyl, norbornyl, adamantyl, and
cyclooctadienyl. In some embodiments, the cycloalkyl has 3-6
carbons. The terms "cycloaliphatic", "carbocycle" or "carbocyclic"
also include aliphatic rings that are fused to one or more aromatic
or nonaromatic rings, such as decahydronaphthyl or
tetrahydronaphthyl, where the radical or point of attachment is on
the aliphatic ring. In certain embodiments, the term "3- to
7-membered carbocycle" refers to a 3- to 7-membered saturated or
partially unsaturated monocyclic carbocyclic ring. In certain
embodiments, the term "3- to 8-membered carbocycle" refers to a 3-
to 8-membered saturated or partially unsaturated monocyclic
carbocyclic ring. In certain embodiments, the terms "3- to
14-membered carbocycle" and "C.sub.3-14 carbocycle" refer to a 3-
to 8-membered saturated or partially unsaturated monocyclic
carbocyclic ring, or a 7- to 14-membered saturated or partially
unsaturated polycyclic carbocyclic ring.
[0026] The term "alkyl," as used herein, refers to saturated,
straight- or branched-chain hydrocarbon radicals derived from an
aliphatic moiety containing between one and six carbon atoms by
removal of a single hydrogen atom. Unless otherwise specified,
alkyl groups contain 1-12 carbon atoms. In certain embodiments,
alkyl groups contain 1-8 carbon atoms. In certain embodiments,
alkyl groups contain 1-6 carbon atoms. In some embodiments, alkyl
groups contain 1-5 carbon atoms, in some embodiments, alkyl groups
contain 1-4 carbon atoms, in some embodiments alkyl groups contain
1-3 carbon atoms, and in some embodiments alkyl groups contain 1-2
carbon atoms. Examples of alkyl radicals include, but are not
limited to, methyl, ethyl, n-propyl, isopropyl, n-butyl, iso-butyl,
sec-butyl, sec-pentyl, iso-pentyl, tert-butyl, n-pentyl, neopentyl,
n-hexyl, sec-hexyl, n-heptyl, n-octyl, n-decyl, n-undecyl, dodecyl,
and the like.
[0027] The term "alkenyl," as used herein, denotes a monovalent
group derived from a straight- or branched-chain aliphatic moiety
having at least one carbon-carbon double bond by the removal of a
single hydrogen atom. Unless otherwise specified, alkenyl groups
contain 2-12 carbon atoms. In certain embodiments, alkenyl groups
contain 2-8 carbon atoms. In certain embodiments, alkenyl groups
contain 2-6 carbon atoms. In some embodiments, alkenyl groups
contain 2-5 carbon atoms, in some embodiments, alkenyl groups
contain 2-4 carbon atoms, in some embodiments alkenyl groups
contain 2-3 carbon atoms, and in some embodiments alkenyl groups
contain 2 carbon atoms. Alkenyl groups include, for example,
ethenyl, propenyl, butenyl, 1-methyl-2-buten-1-yl, and the
like.
[0028] The term "alkynyl," as used herein, refers to a monovalent
group derived from a straight- or branched-chain aliphatic moiety
having at least one carbon-carbon triple bond by the removal of a
single hydrogen atom. Unless otherwise specified, alkynyl groups
contain 2-12 carbon atoms. In certain embodiments, alkynyl groups
contain 2-8 carbon atoms. In certain embodiments, alkynyl groups
contain 2-6 carbon atoms. In some embodiments, alkynyl groups
contain 2-5 carbon atoms, in some embodiments, alkynyl groups
contain 2-4 carbon atoms, in some embodiments alkynyl groups
contain 2-3 carbon atoms, and in some embodiments alkynyl groups
contain 2 carbon atoms. Representative alkynyl groups include, but
are not limited to, ethynyl, 2-propynyl (propargyl), 1-propynyl,
and the like.
[0029] The term "alkoxy", as used herein refers to an alkyl group,
as previously defined, attached to the parent molecule through an
oxygen atom. Examples of alkoxy, include but are not limited to,
methoxy, ethoxy, propoxy, isopropoxy, n-butoxy, tert-butoxy,
neopentoxy, and n-hexoxy.
[0030] The term "acyl", as used herein, refers to a
carbonyl-containing functionality, e.g., --C(.dbd.O)R', wherein R'
is hydrogen or an optionally substituted aliphatic,
heteroaliphatic, heterocyclic, aryl, heteroaryl group, or is a
substituted (e.g., with hydrogen or aliphatic, heteroaliphatic,
aryl, or heteroaryl moieties) oxygen or nitrogen containing
functionality (e.g., forming a carboxylic acid, ester, or amide
functionality). The term "acyloxy", as used here, refers to an acyl
group attached to the parent molecule through an oxygen atom.
[0031] The term "aryl" used alone or as part of a larger moiety as
in "aralkyl", "aralkoxy", or "aryloxyalkyl", refers to monocyclic
and polycyclic ring systems having a total of five to 20 ring
members, wherein at least one ring in the system is aromatic and
wherein each ring in the system contains three to twelve ring
members. The term "aryl" may be used interchangeably with the term
"aryl ring". In certain embodiments of the present invention,
"aryl" refers to an aromatic ring system which includes, but is not
limited to, phenyl, biphenyl, naphthyl, anthracyl and the like,
which may bear one or more substituents. Also included within the
scope of the term "aryl", as it is used herein, is a group in which
an aromatic ring is fused to one or more additional rings, such as
benzofuranyl, indanyl, phthalimidyl, naphthimidyl, phenanthridinyl,
or tetrahydronaphthyl, and the like. In certain embodiments, the
terms "6- to 10-membered aryl" and "C.sub.6-10 aryl" refer to a
phenyl or an 8- to 10-membered polycyclic aryl ring.
[0032] The terms "heteroaryl" and "heteroar-", used alone or as
part of a larger moiety, e.g., "heteroaralkyl", or
"heteroaralkoxy", refer to groups having 5 to 14 ring atoms,
preferably 5, 6, 9 or 10 ring atoms; having 6, 10, or 14 .pi.
electrons shared in a cyclic array; and having, in addition to
carbon atoms, from one to five heteroatoms. The term "heteroatom"
refers to nitrogen, oxygen, or sulfur, and includes any oxidized
form of nitrogen or sulfur, and any quaternized form of a basic
nitrogen. Heteroaryl groups include, without limitation, thienyl,
furanyl, pyrrolyl, imidazolyl, pyrazolyl, triazolyl, tetrazolyl,
oxazolyl, isoxazolyl, oxadiazolyl, thiazolyl, isothiazolyl,
thiadiazolyl, pyridyl, pyridazinyl, pyrimidinyl, pyrazinyl,
indolizinyl, purinyl, naphthyridinyl, benzofuranyl and pteridinyl.
The terms "heteroaryl" and "heteroar-", as used herein, also
include groups in which a heteroaromatic ring is fused to one or
more aryl, cycloaliphatic, or heterocyclyl rings, where the radical
or point of attachment is on the heteroaromatic ring. Nonlimiting
examples include indolyl, isoindolyl, benzothienyl, benzofuranyl,
dibenzofuranyl, indazolyl, benzimidazolyl, benzthiazolyl, quinolyl,
isoquinolyl, cinnolinyl, phthalazinyl, quinazolinyl, quinoxalinyl,
4H-quinolizinyl, carbazolyl, acridinyl, phenazinyl, phenothiazinyl,
phenoxazinyl, tetrahydroquinolinyl, tetrahydroisoquinolinyl, and
pyrido[2,3-b]-1,4-oxazin-3(4H)-one. A heteroaryl group may be mono-
or bicyclic. The term "heteroaryl" may be used interchangeably with
the terms "heteroaryl ring", "heteroaryl group", or
"heteroaromatic", any of which terms include rings that are
optionally substituted. The term "heteroaralkyl" refers to an alkyl
group substituted by a heteroaryl, wherein the alkyl and heteroaryl
portions independently are optionally substituted. In certain
embodiments, the term "5- to 10-membered heteroaryl" refers to a 5-
to 6-membered heteroaryl ring having 1 to 3 heteroatoms
independently selected from nitrogen, oxygen, or sulfur, or an 8-
to 10-membered bicyclic heteroaryl ring having 1 to 4 heteroatoms
independently selected from nitrogen, oxygen, or sulfur. In certain
embodiments, the term "5- to 12-membered heteroaryl" refers to a 5-
to 6-membered heteroaryl ring having 1 to 3 heteroatoms
independently selected from nitrogen, oxygen, or sulfur, or an 8-
to 12-membered bicyclic heteroaryl ring having 1 to 4 heteroatoms
independently selected from nitrogen, oxygen, or sulfur.
[0033] As used herein, the terms "heterocycle", "heterocyclyl",
"heterocyclic radical", and "heterocyclic ring" are used
interchangeably and refer to a stable 5- to 7-membered monocyclic
or 7-14-membered polycyclic heterocyclic moiety that is either
saturated or partially unsaturated, and having, in addition to
carbon atoms, one or more, preferably one to four, heteroatoms, as
defined above. When used in reference to a ring atom of a
heterocycle, the term "nitrogen" includes a substituted nitrogen.
As an example, in a saturated or partially unsaturated ring having
0-3 heteroatoms selected from oxygen, sulfur or nitrogen, the
nitrogen may be N (as in 3,4-dihydro-2H-pyrrolyl), NH (as in
pyrrolidinyl), or .sup.+NR (as in N-substituted pyrrolidinyl). In
some embodiments, the term "3- to 7-membered heterocyclic" refers
to a 3- to 7-membered saturated or partially unsaturated monocyclic
heterocyclic ring having 1 to 2 heteroatoms independently selected
from nitrogen, oxygen, or sulfur. In some embodiments, the term "3-
to 12-membered heterocyclic" refers to a 3- to 8-membered saturated
or partially unsaturated monocyclic heterocyclic ring having 1 to 2
heteroatoms independently selected from nitrogen, oxygen, or
sulfur, or a 7- to 12-membered saturated or partially unsaturated
polycyclic heterocyclic ring having 1-3 heteroatoms independently
selected from nitrogen, oxygen, or sulfur.
[0034] A heterocyclic ring can be attached to its pendant group at
any heteroatom or carbon atom that results in a stable structure
and any of the ring atoms can be optionally substituted. Examples
of such saturated or partially unsaturated heterocyclic radicals
include, without limitation, tetrahydrofuranyl, tetrahydrothienyl,
pyrrolidinyl, pyrrolidonyl, piperidinyl, pyrrolinyl,
tetrahydroquinolinyl, tetrahydroisoquinolinyl, decahydroquinolinyl,
oxazolidinyl, piperazinyl, dioxanyl, dioxolanyl, diazepinyl,
oxazepinyl, thiazepinyl, morpholinyl, and quinuclidinyl. The terms
"heterocycle", "heterocyclyl", "heterocyclyl ring", "heterocyclic
group", "heterocyclic moiety", and "heterocyclic radical", are used
interchangeably herein, and also include groups in which a
heterocyclyl ring is fused to one or more aryl, heteroaryl, or
cycloaliphatic rings, such as indolinyl, 3H-indolyl, chromanyl,
phenanthridinyl, or tetrahydroquinolinyl, where the radical or
point of attachment is on the heterocyclyl ring. A heterocyclyl
group may be mono- or bicyclic. The term "heterocyclylalkyl" refers
to an alkyl group substituted by a heterocyclyl, wherein the alkyl
and heterocyclyl portions independently are optionally
substituted.
[0035] As used herein, the term "partially unsaturated" refers to a
ring moiety that includes at least one double or triple bond. The
term "partially unsaturated" is intended to encompass rings having
multiple sites of unsaturation, but is not intended to include aryl
or heteroaryl moieties, as herein defined.
[0036] As described herein, compounds of the invention may contain
"optionally substituted" moieties. In general, the term
"substituted", whether preceded by the term "optionally" or not,
means that one or more hydrogens of the designated moiety are
replaced with a suitable substituent. Unless otherwise indicated,
an "optionally substituted" group may have a suitable substituent
at each substitutable position of the group, and when more than one
position in any given structure may be substituted with more than
one substituent selected from a specified group, the substituent
may be either the same or different at every position. Combinations
of substituents envisioned by this invention are preferably those
that result in the formation of stable or chemically feasible
compounds. The term "stable", as used herein, refers to compounds
that are not substantially altered when subjected to conditions to
allow for their production, detection, and, in certain embodiments,
their recovery, purification, and use for one or more of the
purposes disclosed herein.
[0037] Suitable monovalent substituents on a substitutable carbon
atom of an "optionally substituted" group are independently
halogen; --(CH.sub.2).sub.0-4R.sup..smallcircle.;
--(CH.sub.2).sub.0-4R.sup..smallcircle.;
--O--(CH.sub.2).sub.0-4C(O)OR.sup..smallcircle.;
--(CH.sub.2).sub.0-4CH(OR.sup..smallcircle.).sub.2;
--(CH.sub.2).sub.0-4SR.sup..smallcircle.; --(CH.sub.2).sub.0-4Ph,
which may be substituted with R.sup..smallcircle.;
--(CH.sub.2).sub.0-4O(CH.sub.2).sub.0-1Ph which may be substituted
with R.sup..smallcircle.; --CH.dbd.CHPh, which may be substituted
with R.sup..smallcircle.; --NO.sub.2; --CN; --N.sub.3;
--(CH.sub.2).sub.0-4N(R.sup..smallcircle.).sub.2;
--(CH.sub.2).sub.0-4N(R.sup..smallcircle.)C(O)R.sup..smallcircle.;
--N(R.sup..smallcircle.)C(S)R.sup..smallcircle.;
--(CH.sub.2).sub.0-4N(R.sup..smallcircle.)C(O)NR.sup..smallcircle..sub.2;
--N(R.sup..smallcircle.)C(S)NR.sup..smallcircle..sub.2;
--(CH.sub.2).sub.0-4N(R.sup..smallcircle.)C(O)OR.sup..smallcircle.;
--N(R.sup..smallcircle.)N(R.sup..smallcircle.)C(O)R.sup..smallcircle.;
--N(R.sup..smallcircle.)N(R.sup..smallcircle.)C(O)NR.sup..smallcircle..su-
b.2;
--N(R.sup..smallcircle.)N(R.sup..smallcircle.)C(O)OR.sup..smallcircle-
.; --(CH.sub.2).sub.0-4C(O)R.sup..smallcircle.;
--C(S)R.sup..smallcircle.; --(CH.sub.2).sub.0
4C(O)OR.sup..smallcircle.; --(CH.sub.2).sub.0
4C(O)N(R.sup..smallcircle.).sub.2; --(CH.sub.2).sub.0
4C(O)SR.sup..smallcircle.;
--(CH.sub.2).sub.0-4C(O)OSiR.sup..smallcircle..sub.3;
--(CH.sub.2).sub.0-4OC(O)R.sup..smallcircle.;
--OC(O)(CH.sub.2).sub.0-4SR--, SC(S)SR.sup..smallcircle.;
--(CH.sub.2).sub.0-4SC(O)R.sup..smallcircle.;
--(CH.sub.2).sub.0-4C(O)NR.sup..smallcircle..sub.2;
--C(S)NR.sup..smallcircle..sub.2; --C(S)SR.sup..smallcircle.;
--SC(S)SR.sup..smallcircle.,
--(CH.sub.2).sub.0-4OC(O)NR.sup..smallcircle..sub.2;
--C(O)N(OR.sup..smallcircle.)R.sup..smallcircle.;
--C(O)C(O)R.sup..smallcircle.;
--C(O)CH.sub.2C(O)R.sup..smallcircle.; --C(NOR)R.sup..smallcircle.;
--(CH.sub.2).sub.0-4SSR.sup..smallcircle.;
--(CH.sub.2).sub.0-4S(O).sub.2R.sup..smallcircle.;
--(CH.sub.2).sub.0-4S(O).sub.2OR.sup..smallcircle.;
--(CH.sub.2).sub.0-4)S(O).sub.2R;
--S(O).sub.2NR.sup..smallcircle..sub.2;
--(CH.sub.2).sub.0-4S(O)R.sup..smallcircle.;
--N(R.sup..smallcircle.)S(O).sub.2NR.sup..smallcircle..sub.2;
--N(R.sup..smallcircle.)S(O).sub.2R.sup..smallcircle.;
--N(OR.sup..smallcircle.)R.sup..smallcircle.;
--C(NH)NR.sup..smallcircle..sub.2; --P(O).sub.2R.sup..smallcircle.;
--P(O)R.sup..smallcircle..sub.2; --OP(O)R.sup..smallcircle..sub.2;
--OP(O)(OR.sup..smallcircle.).sub.2; SiR.sup..smallcircle..sub.3;
--(C.sub.1-4 straight or branched
alkylene)O--N(R.sup..smallcircle.).sub.2; or --(C.sub.1-4 straight
or branched alkylene)C(O)O--N(R.sup..smallcircle.).sub.2, wherein
each R.sup..smallcircle. may be substituted as defined below and is
independently hydrogen, C.sub.1-8 aliphatic, --CH.sub.2Ph,
--O(CH.sub.2).sub.0-1Ph, or a 5-6-membered saturated, partially
unsaturated, or aryl ring having 0-4 heteroatoms independently
selected from nitrogen, oxygen, or sulfur, or, notwithstanding the
definition above, two independent occurrences of
R.sup..smallcircle., taken together with their intervening atom(s),
form a 3-12-membered saturated, partially unsaturated, or aryl
mono- or polycyclic ring having 0-4 heteroatoms independently
selected from nitrogen, oxygen, or sulfur, which may be substituted
as defined below.
[0038] Suitable monovalent substituents on R.sup..smallcircle. (or
the ring formed by taking two independent occurrences of
R.sup..smallcircle. together with their intervening atoms), are
independently halogen, --(CH.sub.2).sub.0-2R.sup. , -(haloR.sup. ),
--(CH.sub.2).sub.0-2OH, --(CH.sub.2).sub.0-2OR.sup. ,
--(CH.sub.2).sub.0-2CH(OR.sup. ).sub.2; --O(haloR.sup. ), --CN,
--N.sub.3, --(CH.sub.2).sub.0-2C(O)R.sup. ,
--(CH.sub.2).sub.0-2C(O)OH, --(CH.sub.2).sub.0-2C(O)OR.sup. ,
--(CH.sub.2).sub.0-4--C(O)N(R.sup..smallcircle.).sub.2;
--(CH.sub.2).sub.0-2SR.sup. , --(CH.sub.2).sub.0-2SH,
--(CH.sub.2).sub.0-2NH.sub.2, --(CH.sub.2).sub.0-2NHR.sup. ,
--(CH.sub.2).sub.0 2NR.sup. .sub.2, --NO.sub.2, --SiR.sup. .sub.3,
--OSiR.sup. .sub.3, --C(O)SR.sup. , --(C.sub.1 4 straight or
branched alkylene)C(O)OR.sup. , or --SSR.sup. wherein each R.sup.
is unsubstituted or where preceded by "halo" is substituted only
with one or more halogens, and is independently selected from
C.sub.1-4 aliphatic, --CH.sub.2Ph, --O(CH.sub.2).sub.0-1Ph, or a
5-6-membered saturated, partially unsaturated, or aryl ring having
0-4 heteroatoms independently selected from nitrogen, oxygen, or
sulfur. Suitable divalent substituents on a saturated carbon atom
of R.sup..smallcircle. include --O and --S.
[0039] Suitable divalent substituents on a saturated carbon atom of
an "optionally substituted" group include the following: .dbd.O,
--S, --NNR*.sub.2, --NNHC(O)R*, .dbd.NNHC(O)OR*,
.dbd.NNHS(O).sub.2R*, .dbd.NR*, .dbd.NOR*,
--O(C(R*.sub.2)).sub.2-3O--, or --S(C(R*.sub.2)).sub.2-3S--,
wherein each independent occurrence of R* is selected from
hydrogen, C.sub.1-6 aliphatic which may be substituted as defined
below, or an unsubstituted 5-6-membered saturated, partially
unsaturated, or aryl ring having 0-4 heteroatoms independently
selected from nitrogen, oxygen, or sulfur. Suitable divalent
substituents that are bound to vicinal substitutable carbons of an
"optionally substituted" group include: --O(CR*.sub.2).sub.2-3O--,
wherein each independent occurrence of R* is selected from
hydrogen, C.sub.1-6 aliphatic which may be substituted as defined
below, or an unsubstituted 5-6-membered saturated, partially
unsaturated, or aryl ring having 0-4 heteroatoms independently
selected from nitrogen, oxygen, or sulfur.
[0040] Suitable substituents on the aliphatic group of R* include
halogen, --R.sup. , -(haloR.sup. ), --OH, --OR.sup. ,
--O(haloR.sup. ), --CN, --C(O)OH, --C(O)OR.sup. , --NH.sub.2,
--NHR.sup. , --NR.sup. .sub.2, or --NO.sub.2, wherein each R.sup.
is unsubstituted or where preceded by "halo" is substituted only
with one or more halogens, and is independently C.sub.1-4
aliphatic, --CH.sub.2Ph, --O(CH.sub.2).sub.0-1Ph, or a 5-6-membered
saturated, partially unsaturated, or aryl ring having 0-4
heteroatoms independently selected from nitrogen, oxygen, or
sulfur.
[0041] Suitable substituents on a substitutable nitrogen of an
"optionally substituted" group include --R.sup..dagger.,
--NR.sup..dagger..sub.2, --C(O)R.sup..dagger.,
--C(O)OR.sup..dagger., --C(O)C(O)R.sup..dagger.,
--C(O)CH.sub.2C(O)R.sup..dagger., --S(O).sub.2R.sup..dagger.,
--S(O).sub.2NR.sup..dagger..sub.2, --C(S)NR.sup..dagger..sub.2,
--C(NH)NR.sup..dagger..sub.2, or
--N(R.sup..dagger.)S(O).sub.2R.sup..dagger.; wherein each
R.sup..dagger. is independently hydrogen, C.sub.1-6 aliphatic which
may be substituted as defined below, unsubstituted --OPh, or an
unsubstituted 5-6-membered saturated, partially unsaturated, or
aryl ring having 0-4 heteroatoms independently selected from
nitrogen, oxygen, or sulfur, or, notwithstanding the definition
above, two independent occurrences of R.sup..dagger., taken
together with their intervening atom(s) form an unsubstituted
3-12-membered saturated, partially unsaturated, or aryl mono- or
bicyclic ring having 0-4 heteroatoms independently selected from
nitrogen, oxygen, or sulfur.
[0042] Suitable substituents on the aliphatic group of
R.sup..dagger. are independently halogen, --R.sup. , -(haloR.sup.
), --OH, --OR.sup. , --O(haloR.sup. ), --CN, --C(O)OH,
--C(O)OR.sup. , --NH.sub.2, --NHR.sup. , --NR.sup. .sub.2, or
--NO.sub.2, wherein each R.sup. is unsubstituted or where preceded
by "halo" is substituted only with one or more halogens, and is
independently C.sub.1-4 aliphatic, --CH.sub.2Ph,
--O(CH.sub.2).sub.0-1Ph, or a 5-6-membered saturated, partially
unsaturated, or aryl ring having 0-4 heteroatoms independently
selected from nitrogen, oxygen, or sulfur.
[0043] When substituents are described herein, the term "radical"
or "optionally substituted radical" is sometimes used. In this
context, "radical" means a moiety or functional group having an
available position for attachment to the structure on which the
substituent is bound. In general the point of attachment would bear
a hydrogen atom if the substituent were an independent neutral
molecule rather than a substituent. The terms "radical" or
"optionally-substituted radical" in this context are thus
interchangeable with "group" or "optionally-substituted group".
[0044] As used herein, the "term head-to-tail" or "HT", refers to
the regiochemistry of adjacent repeating units in a polymer chain.
For example, in the context of poly(propylene carbonate) (PPC), the
term head-to-tail based on the three regiochemical possibilities
depicted below:
##STR00002##
[0045] The term "head-to-tail ratio" or (H:T) refers to the
proportion of head-to-tail linkages to the sum of all other
regiochemical possibilities. With respect to the depiction of
polymer structures, while a specific regiochemical orientation of
monomer units may be shown in the representations of polymer
structures herein, this is not intended to limit the polymer
structures to the regiochemical arrangement shown but is to be
interpreted to encompass all regiochemical arrangements including
that depicted, the opposite regiochemistry, random mixtures,
isotactic materials, syndiotactic materials, racemic materials,
and/or enantioenriched materials and combinations of any of these
unless otherwise specified.
[0046] As used herein the term "alkoxylated" means that one or more
functional groups on a molecule (usually the functional group is an
alcohol, amine, or carboxylic acid, but is not strictly limited to
these) has appended to it a hydroxy-terminated alkyl chain.
Alkoxylated compounds may comprise a single alkyl group or they may
be oligomeric moieties such as hydroxyl-terminated polyethers.
Alkoxylated materials can be derived from the parent compounds by
treatment of the functional groups with epoxides.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] FIG. 1 Shows a chart of the load bearing (CFD) data from PU
foams with and without 58-103-C Polyol.
[0048] FIG. 2 Shows a chart of the load bearing (CFD) data from PU
foams with and without 74-276 Polyol.
[0049] FIG. 3 Shows a chart of the density-normalized load bearing
data from PU foams with and without additives of the present
invention and with other additives.
[0050] FIG. 4 Shows a chart of the comfort factor data (SAG value)
for PU foams with and without additives of the present invention
and with other additives.
[0051] FIG. 5 Shows a chart of the comfort factor data (SAG value)
for PU foams with and without additives of the present invention
and with other additives.
[0052] FIG. 6 Shows a graph comparing CFD values for certain
viscoclastic (VE) foams of the present invention with reference
foams.
[0053] FIG. 7 Shows a graph comparing CFD values for certain VE
foams of the present invention with reference foams.
[0054] FIG. 8 Shows a graph comparing hysteresis of certain VE
foams of the present invention with reference foams.
[0055] FIG. 9 Shows a graph comparing CFD values for certain VE
foams of the present invention with reference foams.
[0056] FIG. 10 Shows a graph comparing CFD values for certain VE
foams of the present invention with reference foams.
[0057] FIG. 11 Shows a graph comparing hysteresis of certain VE
foams of the present invention with reference foams.
[0058] FIG. 12 Shows a graph comparing CFD values for certain VE
foams of the present invention with reference foams.
[0059] FIG. 13 Shows a graph comparing CFD values for certain VE
foams of the present invention with reference foams.
[0060] FIG. 14 Shows a graph comparing hysteresis of certain VE
foams of the present invention with reference foams.
[0061] FIG. 15 Shows a graph comparing CFD values for certain VE
foams of the present invention with reference foams.
[0062] FIG. 16 Shows a graph comparing CFD values for certain VE
foams of the present invention with reference foams.
[0063] FIG. 17 Shows a graph comparing hysteresis of certain VE
foams of the present invention with reference foams.
[0064] FIG. 18 Shows DMA graphs for a reference VE foam and a VE
foam prepared according to the present invention.
[0065] FIG. 19 Shows DMA graphs for two VE foam samples prepared
according to the present invention.
[0066] FIG. 20 Shows DMA graphs for two VE foam samples prepared
according to the present invention.
[0067] FIG. 21 Shows DSC graphs for a reference VE foam and a VE
foam prepared according to the present invention.
[0068] FIG. 22 Shows DSC graphs for two VE foam samples prepared
according to the present invention.
[0069] FIG. 23 Shows DSC graphs for two VE foam samples prepared
according to the present invention.
[0070] FIG. 24 Shows a chart of the resilience properties of PU
foams based on Novomer and Commercial Polyols.
[0071] FIG. 25 Shows a chart of the hysteresis properties of PU
foams based on Novomer and Commercial Polyols.
[0072] FIG. 26 Shows a chart of the load bearing properties of PU
foams based on Novomer and Commercial Polyols.
[0073] FIG. 27 Shows a chart of the load bearing properties of PU
foams based on Novomer and Commercial Polyols.
[0074] FIG. 28 Shows a chart of the load bearing properties of PU
foams based on Novomer and Commercial Polyols.
[0075] FIG. 29 Shows a chart of the Normalized load bearing
properties of PU foams based on Novomer and Commercial Polyols.
[0076] FIG. 30 Shows a chart of the Normalized load bearing
properties of PU foams based on Novomer and Commercial Polyols.
[0077] FIG. 31 Shows a chart of the Normalized load bearing
properties of PU foams based on Novomer and Commercial Polyols.
[0078] FIG. 32 Shows a chart of support factor data for PU foams
based on Novomer and Commercial Polyols.
[0079] FIG. 33 Shows Chrysler Material Standard: MS-DC-649 for
"Cellular, Molded Polyurethane High Resilient (HR) Type Seat
Applications".
DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS
[0080] The field of polyurethane manufacture and formulation is
well advanced. In some embodiments, the novel materials presented
herein are formulated, processed, and used according to methods
well known in the art. Combining knowledge of the art, with the
disclosure and teachings herein, the skilled artisan will readily
apprehend variations, modifications and applications of the
compositions and such variations are specifically encompassed
herein. The following references contain information on the
formulation, manufacture and uses of polyurethane foams and
elastomers, the entire content of each of these references is
incorporated herein by reference. [0081] Vahid Sendijarevic, et
al.; Polymeric Foams And Foam Technology, 2.sup.nd edition, Hanser
Gardner Publications; 2004 (ISBN 978-1569903360) [0082] David
Eaves; Handbook of Polymer Foams. Smithers Rapra Press; 2004 (ISBN
978-1859573884) [0083] Shau-Tarng Lee et al.; Polymeric Foams:
Science and Technology. CRC Press 2006 (ISBN 978-0849330759) [0084]
Kaneyoshi Ashida; Polyurethane and Related Foams: Chemistry and
Technology. CRC Press; 2006 (ISBN 978-1587161599) [0085] Handbook
of Thermoplastic Elastomers. William Andrew Publishers, 2007 (ISBN
978-0815515494) [0086] The Polyurethanes Book, J. Wiley & Sons,
2003 (ISBN 978-0470850411)
I. Methods of Strengthening Polyurethane Foams
[0087] Commercial polyurethane foam compositions are typically
manufactured by combining two components: an isocyanate component
containing one or more polyisocyanate compounds optionally blended
with additional materials such as diluents, solvents, coreactants
and the like (often referred to in the art as an A-side mixture),
and a polyol component comprising one or more polyols optionally
blended with additional reactants, solvents, catalysts, or
additives (typically referred to in the art as the B side
mixture).
[0088] In certain embodiments, methods of the present invention
include a step of substituting a portion of the polyol component of
a polyurethane foam composition with a strength enhancing additive
comprising an aliphatic polycarbonate polyol derived from the
copolymerization of CO.sub.2 and one or more epoxides.
[0089] In certain embodiments, the method entails replacing between
about 1 weight and about 50 weight percent of the polyol content of
a polyurethane foam formulation with an aliphatic polycarbonate
polyol. In certain embodiments, the aliphatic polycarbonate polyol
used for this purpose has a primary polymer repeat unit with the
structure:
##STR00003## [0090] wherein R.sup.1 is, at each occurrence in the
polymer chain, independently --H, --CH.sub.3, or
--CH.sub.2CH.sub.3.
[0091] In certain embodiments, the present invention provides a
method for increasing the load bearing properties of a polyurethane
foam composition, the foam composition comprising the reaction
product of a polyol component and a polyisocyanate component, the
method comprising the step of incorporating into the polyol
component a polycarbonate polyol derived from the copolymerization
of one or more epoxides and carbon dioxide. In certain embodiments,
the polycarbonate polyol is added in a quantity from about 1 weight
percent to about 50 weight percent of all polyols present in the
polyol component of the foam formulation. In certain embodiments,
the added polycarbonate polyol is provided in a quantity from about
2 weight percent to about 50 weight percent of all polyols present
in the polyol component of the foam formulation. In certain
embodiments, the added polycarbonate polyol is provided in a
quantity from about 5 weight percent, to about 25 weight percent of
all polyol percent in the polyol component. In certain embodiments,
the added polycarbonate polyol is provided in a quantity from about
1 weight percent to about 2 weight percent of all polyol present in
the polyol component. In certain embodiments, the added
polycarbonate polyol is provided in a quantity from about 2 weight
percent to about 5 weight percent of all polyol present in the
polyol component. In certain embodiments, the added polycarbonate
polyol is provided in a quantity from about 2 weight percent to
about 10 weight percent of all polyol present in the polyol
component In certain embodiments, the added polycarbonate polyol is
provided in a quantity from about 5 weight percent to about 10
weight percent of all polyol present in the polyol component. In
certain embodiments, the added polycarbonate polyol is provided in
a quantity from about 10 weight percent, to about 20 weight percent
of all polyol present in the polyol component. In certain
embodiments, the added polycarbonate polyol is provided in a
quantity from about 20 weight percent, to about 30 weight percent
of all polyol present in the polyol component. In certain
embodiments, the added polycarbonate polyol is provided in a
quantity from about 30 weight percent, to about 50 weight percent
of all polyol present in the polyol component. In certain
embodiments, the added polycarbonate polyol is provided in a
quantity of about 1 weight percent of all polyol present in the
polyol component. In certain embodiments, the added polycarbonate
polyol is provided in a quantity of about 2 weight percent of all
polyol present in the polyol component. In certain embodiments, the
added polycarbonate polyol is provided in a quantity of about 3
weight percent of all polyol present in the polyol component. In
certain embodiments, the added polycarbonate polyol is provided in
a quantity of about 5 weight percent of all polyol present in the
polyol component. In certain embodiments, the added polycarbonate
polyol is provided in a quantity of about 10 weight percent of all
polyol present in the polyol component. In certain embodiments, the
added polycarbonate polyol is provided in a quantity of about 15
weight percent of all polyol present in the polyol component. In
certain embodiments, the added polycarbonate polyol is provided in
a quantity of about 20 weight percent of all polyol present in the
polyol component. In certain embodiments, the added polycarbonate
polyol is provided in a quantity of about 25 weight percent of all
polyol present in the polyol component. In certain embodiments, the
added polycarbonate polyol is provided in a quantity of about 30
weight percent of all polyol present in the polyol component. In
certain embodiments, the added polycarbonate polyol is provided in
a quantity of about 40 weight percent of all polyol present in the
polyol component.
[0092] In certain embodiments, the other polyols present in the
polyol component to which the aliphatic polycarbonate polyol is
added are selected from the group consisting of: polyether polyols,
polyester polyols, polybutadiene polyols, polysulfide polyols,
natural oil polyols, fluorinated polyols, aliphatic polyols,
polyethercarbonate polyols, polycarbonate polyols other than those
derived from epoxide-CO.sub.2 copolymerization, and mixtures of any
two or more these. In certain embodiments, between about 50 percent
and about 99 percent of the total weight of polyol present in the
polyol component (i.e. exclusive of any other non-polyol components
that may be present in a B-side composition for foams such as
catalysts, cell openers, blowing agents, stabilizers, diluents,
pigments and the like) comprises one or more polyols selected from
the group consisting of polyether polyols, polyester polyols,
polybutadiene polyols, polysulfide polyols, natural oil polyols,
fluorinated polyols, aliphatic polyols, polycarbonate polyols other
than those derived from epoxide-CO.sub.2 copolymerization, and
mixtures of any two or more these. In certain embodiments, the
other polyol present in the polyol component to which the aliphatic
polycarbonate polyol is added substantially comprises polyether
polyol. In certain embodiments, the other polyol present in the
polyol component to which the aliphatic polycarbonate polyol is
added substantially comprises polyester polyol. In certain
embodiments, the other polyols present in the polyol component to
which the aliphatic polycarbonate polyol is added substantially
comprise a mixture of polyether and polyester polyols.
[0093] In certain embodiments, methods of the present invention
comprise formulating a high strength flexible polyurethane foam
composition by providing a polycarbonate polyol derived from the
copolymerization of one or more epoxides and carbon dioxide as a
polyol component in a B-side composition comprising a polyether
polyol. In certain embodiments the polycarbonate polyol is provided
in such a quantity that the final B-side composition contains from
about 1 part to about 100 parts by weight of polycarbonate polyol
based on 100 parts of polyether polyol. In certain embodiments, the
polycarbonate polyol is added in such a quantity that the
polycarbonate polyol comprises about 5 parts, about 10 parts, about
20 parts, about 30 parts, about 40 parts, about 60 parts, about 80
parts, or about 100 parts, based on 100 parts of polyether polyol
in the resulting B-side formulation. In certain embodiments, the
aliphatic polycarbonate polyol comprises poly(propylene carbonate).
In certain embodiments, the aliphatic polycarbonate polyol added
comprises poly(ethylene carbonate). In certain embodiments, the
aliphatic polycarbonate polyol added comprises
poly(ethylene-co-propylene carbonate). In certain embodiments, the
method comprises the additional steps of stirring and/or heating a
mixture of the aliphatic polycarbonate polyol and the polyether
polyol. In certain embodiments, the method comprising the step of
stirring and/or heating is performed until a substantially
homogenous mixture of the polycarbonate polyol and the polyether
polyol is formed.
[0094] In certain embodiments, the methods of the present invention
are characterized in that foams formulated using the methods have
higher strength than corresponding foams formulated without the
step of providing the polycarbonate polyol. In certain embodiments,
the methods are characterized in that one or more properties
selected from the group consisting of: Tensile Strength at Break
(as measured by ASTM D3574-08 Test E); Tear Strength (as measured
by ASTM D3574-08 Test F); Compression Force Deflection (CFD) (as
measured by ASTM D3574-08 Test C); and Tensile strength and
Elongation after Dry Heat Aging for 22 hours at 140.degree. C. (as
measured by ASTM D3574-08Test K) are enhanced relative to those of
a corresponding reference foam formulated without the step of
adding the polycarbonate polyol.
[0095] In certain embodiments, the inventive methods are
characterized in that the foams produced have high compression
force deflection. With the existing art, such CFDs can only be
achieved for flexible foams with good comfort properties by
incorporating filled polyols. The use of filled polyols can be
undesirable from a cost perspective and raises concerns due to the
presence of residual VOCs such as styrene. Residual VOCs cause
nuisance odors in the finished foams, and may have negative health
effects for those exposed to articles made from the foam. We have
found that foams strengthened by addition of epoxide CO.sub.2
copolymers have CFD values as measured by ASTM D3574-08 Test C that
are uniquely high, meeting or exceeding those attained by addition
of filled polyols but without the attendant problems associated
with filled polyols. Thus in certain embodiments, the present
invention encompasses methods of making high CFD foams.
[0096] In certain embodiments, the present invention provides
methods of formulating high strength polyurethane foam compositions
(denoted the Strengthened Foam formulation) comprising the step of
adding a polycarbonate polyol derived from the copolymerization of
one or more epoxides and carbon dioxide to a B-side formulation,
the method characterized in that the load bearing capacity of the
strengthened foam as indicated by its compression force deflection
(CFD) value measured by ASTM D3574-08 Test C, is greater than the
CFD value of the corresponding foam composition formulated without
the added polycarbonate polyol denoted the Reference Foam
formulation, (i.e. the comparison is between two foams formulated
similarly but for the substitution of the polycarbonate polyol for
a portion of the polyol present in the B-side of the reference
foam; non-limiting examples of such comparisons are provided in the
Examples section hereinbelow, importantly, for a valid comparison
no other additions or substantial changes in the ratios or
identities of the other foam components are made). In certain
embodiments, the method comprises adding the aliphatic
polycarbonate polyol to the B-side formulation by substituting a
portion of one or more polyols in the reference formulation such
that the --OH number of the B-side formulation for the strengthened
foam is substantially the same as that of the B-side formulation of
the reference foam formulation. In certain embodiments, the method
is characterized in that the CFD value of the strengthened foam
formulation is at least 10% greater than the CFD value of the
reference foam formulation. In certain embodiments, the method is
characterized in that the CFD value of the strengthened foam
formulation is at least 10% greater, at least 20% greater, at least
30% greater, at least 40% greater, at least 50% greater, or at
least 100%/greater than the CFD value of the reference foam. In
certain embodiments, the CFD values of the strengthened foam and
the reference foam are normalized for the density of the foam prior
to comparing them. In certain embodiments the method is
characterized in that the strengthened foam composition and the
reference foam composition have substantially the same density.
[0097] In certain embodiments, the present invention provides
methods of formulating high strength polyurethane foam compositions
(denoted the strengthened foam formulation) comprising the step of
adding a polycarbonate polyol derived from the copolymerization of
one or more epoxides and carbon dioxide to a B-side formulation,
the method characterized in that the strengthened foam formulation
has a lower density than the corresponding foam composition
formulated without the added polycarbonate polyol (denoted the
reference foam formulation) further characterized in that the load
bearing properties (CFD) of the strengthened foam as determined by
ASTM D3574-08 Test C, are equal to or greater than those of the
reference foam. In certain embodiments, the method comprises adding
the aliphatic polycarbonate polyol to the B-side formulation by
substituting a portion of one or more polyols in the reference
formulation such that the --OH number of the B-side formulation for
the strengthened foam is substantially the same as that of the
B-side formulation of the reference foam formulation. In certain
embodiments, the method is characterized in that the density of the
strengthened foam formulation is at least 10% lower than the
density of the reference foam formulation. In certain embodiments,
the method is characterized in that the density of the strengthened
foam formulation is at least 10%, at least 20%, at least 30%, at
least 40%, or at least 50%, less than the density of the reference
foam. In certain embodiments, the method is characterized in that
the density of the strengthened foam formulation is at least 10%,
at least 20%, at least 30%, at least 40%, or at least 50%, less
than the density of the reference foam while the CFD of the
strengthened foam is at least equal to, at least 10% greater than,
at least 20% greater than, at least 30% greater than, at least 40%
greater than, at least 50% greater than, at least 75% greater than,
or at least 100% greater than the CFD of the reference foam.
[0098] In certain embodiments, the method is characterized in that
the Strengthened Foam formulation has the combination of a density
of less than about 2.6 pounds/cubic foot (pcf) and a CFD as
measured by ASTM D3574-08 Test C of at least 0.4 psi at 25%
deflection. In certain embodiments, the method is characterized in
that the CFD value is at least 0.45 psi at 25% deflection, at least
0.5 psi at 25% deflection, or at least 0.52 psi at 25% deflection.
In certain embodiments, the method is characterized in that the CFD
value of the strengthened foam formulation measured by ASTM
D3574-08 Test C is at least 0.5 psi at 50% deflection. In certain
embodiments, the method is characterized in that the CFD value of
the strengthened foam formulation measured by ASTM D3574-08 Test C
is at least 0.55 psi at 50% deflection, at least 0.60 psi at 50%
deflection, at least 0.65 psi at 50% deflection, at least 0.7 psi
at 50% deflection, or at least 0.75 psi at 50% deflection. In
certain embodiments, the method is characterized in that the CFD
value of the strengthened foam formulation measured by ASTM
D3574-08 Test C is at least 0.7 psi at 65% deflection. In certain
embodiments, the method is characterized in that the CFD value of
the strengthened foam formulation measured by ASTM D3574-08 Test C
is at least 0.75 psi at 65% deflection, at least 0.80 psi at 65%
deflection, at least 0.85 psi at 65% deflection, at least 0.9 psi
at 65% deflection, or at least 1 psi at 65% deflection. In certain
embodiments, the CFD values above are for a foam composition having
a density of between about 2 and 2.6 pcf. In certain embodiments,
the CFD values above are for a foam composition having a density of
between about 2.2 and 2.6 pcf, or a density of about 2.4 pcf. In
certain embodiments, the CFD values above are for foams having a
density between about 2 and 2.6 pcf and further characterized in
that they contain less than 10% filled polyol, less than 5% filled
polyol, less than 3% filled polyol, less than 2% filled polyol,
less than 1% filled polyol, or characterized in that they are
substantially free of filled polyol. In certain embodiments, the
foam formulations above are characterized in that they have comfort
properties suitable for use in seating foams.
[0099] In certain embodiments, the method is characterized in that
the Strengthened Foam formulation has the combination of a density
of less than about 4 pcf and a CFD as measured by ASTM D3574-08
Test C of at least 0.8 psi at 25% deflection. In certain
embodiments, the method is characterized in that the CFD value of
the strengthened foam formulation is at least 0.85 psi at 25%
deflection, at least 0.9 psi at 25% deflection, at least 0.95 psi
at 25% deflection, or at least 1 psi at 25% deflection. In certain
embodiments, the method is characterized in that the CFD value of
the strengthened foam formulation with a density of less than about
4 pcf as measured by ASTM D3574-08 Test C is at least 1 psi at 50%
deflection. In certain embodiments, the method is characterized in
that the CFD value is at least 1.1 psi at 50% deflection, at least
1.2 psi at 50% deflection, at least 1.3 psi at 50% deflection, or
at least 1.4 psi at 50% deflection. In certain embodiments, the
method is characterized in that the CFD value of the strengthened
foam formulation with a density of less than about 4 pcf as
measured by ASTM D3574-08 Test C is at least 1.4 psi at 65%
deflection. In certain embodiments, the method is characterized in
that the CFD value of the strengthened foam formulation is at least
1.5 psi at 65% deflection, at least 1.6 psi at 65% deflection, at
least 1.7 psi at 65% deflection, at least 1.8 psi at 65%
deflection, at least 1.9 psi at 65% deflection, or at least 2 psi
at 65% deflection. In certain embodiments, the CFD values above are
for a foam composition having a density of between about 3.2 and
3.8 pcf. In certain embodiments, the CFD values above are for a
foam composition having a density of between about 3.3 and 3.7 pcf,
or a density of about 3.5 pcf. In certain embodiments, the CFD
values above are for foams having a density between about 3.2 and
3.8 pcf and further characterized in that they contain less than
10% filled polyol, less than 5% filled polyol, less than 3% filled
polyol, less than 2% filled polyol, less than 1% filled polyol, or
characterized in that they are substantially free of filled polyol.
In certain embodiments, the foam formulations above are
characterized in that they have comfort properties suitable for use
in seating foams. In certain embodiments, the present invention
provides methods of formulating high strength polyurethane foam
compositions (denoted the strengthened foam formulation) comprising
the step of adding a polycarbonate polyol derived from the
copolymerization of one or more epoxides and carbon dioxide to a
B-side formulation, the method characterized in that the tensile
strength of the strengthened foam as measured by ASTM D 3574-08
Test E, is greater than the tensile strength of the corresponding
foam composition formulated without the added polycarbonate polyol
(denoted the reference foam formulation). In certain embodiments,
the method comprises adding the aliphatic polycarbonate polyol to
the B-side formulation by substituting a portion of one or more
polyols in the reference formulation such that the --OH number of
the B-side formulation for the strengthened foam is substantially
the same as that of the B-side formulation of the reference foam
formulation. In certain embodiments, the method is characterized in
that the tensile strength of the strengthened foam formulation is
at least 10% greater than the tensile strength of the reference
foam formulation. In certain embodiments, the method is
characterized in that the tensile strength of the strengthened foam
formulation is at least 20%, at least 30%, at least 40%, at least
50%, or at least 100% greater than the tensile strength of the
reference foam. In certain embodiments, the tensile strengths of
the strengthened foam and the reference foam are normalized for the
density of the foams prior to comparing them. In certain
embodiments the method is characterized in that the strengthened
foam composition and the reference foam composition have
substantially the same density.
[0100] In certain embodiments, the present invention provides
methods of formulating high strength polyurethane foam compositions
(denoted the strengthened foam formulation) comprising the step of
adding a polycarbonate polyol derived from the copolymerization of
one or more epoxides and carbon dioxide to a B-side formulation,
the method characterized in that the strengthened foam formulation
has a lower density than the corresponding foam composition
formulated without the added polycarbonate polyol (denoted the
reference foam formulation) further characterized in that the
tensile strength of the strengthened foam as determined by ASTM
D3574-08 Test E is equal to or greater than that of the reference
foam. In certain embodiments, the method comprises adding the
aliphatic polycarbonate polyol to the B-side formulation by
substituting a portion of one or more polyols in the reference
formulation such that the --OH number of the B-side formulation for
the strengthened foam is substantially the same as that of the
B-side formulation of the reference foam formulation. In certain
embodiments, the method is characterized in that the density of the
strengthened foam formulation is at least 10% lower than the
density of the reference foam formulation. In certain embodiments,
the method is characterized in that the density of the strengthened
foam formulation is at least 10%, at least 20%, at least 30%, at
least 40%, or at least 50%, less than the density of the reference
foam. In certain embodiments, the method is characterized in that
the density of the strengthened foam formulation is at least 10%,
at least 20%, at least 30%, at least 40%, or at least 50%, less
than the density of the reference foam while the tensile strength
of the strengthened foam is at least equal to, at least 10% greater
than, at least 20% greater than, at least 30% greater than, at
least 40% greater than, at least 50% greater than, at least 75%
greater than, or at least 100% greater than the tensile strength of
the reference foam.
[0101] In certain embodiments, the present invention provides
methods of formulating high strength polyurethane foam compositions
(denoted the strengthened foam formulation) comprising the step of
adding a polycarbonate polyol derived from the copolymerization of
one or more epoxides and carbon dioxide to a B-side formulation,
the method characterized in that the tear strength of the
strengthened foam as measured by ASTM D 3574-08 Test F is greater
than the tear strength of the corresponding foam composition
formulated without the added polycarbonate polyol (denoted the
reference foam formulation). In certain embodiments, the method
comprises adding the aliphatic polycarbonate polyol to the B-side
formulation by substituting a portion of one or more polyols in the
reference formulation such that the --OH number of the B-side
formulation for the strengthened foam is substantially the same as
that of the B-side formulation of the reference foam formulation.
In certain embodiments, the method is characterized in that the
tensile strength of the strengthened foam formulation is at least
10% greater than the tensile strength of the reference foam
formulation. In certain embodiments, the method is characterized in
that the tear strength of the strengthened foam formulation is at
least 20%, at least 30%, at least 40%, at least 50%, or at least
100% greater than the tear strength of the reference foam. In
certain embodiments, the tear strengths of the strengthened foam
and the reference foam are normalized for the density of the foams
prior to comparing them. In certain embodiments the method is
characterized in that the strengthened foam composition and the
reference foam composition have substantially the same density.
[0102] In certain embodiments, the present invention provides
methods of formulating high strength polyurethane foam compositions
(denoted the strengthened foam formulation) comprising the step of
adding a polycarbonate polyol derived from the copolymerization of
one or more epoxides and carbon dioxide to a B-side formulation,
the method characterized in that the strengthened foam formulation
has a lower density than the corresponding foam composition
formulated without the added polycarbonate polyol (denoted the
reference foam formulation) further characterized in that the tear
strength of the strengthened foam as determined by ASTM D3574-08
Test F is equal to or greater than that of the reference foam. In
certain embodiments, the method comprises adding the aliphatic
polycarbonate polyol to the B-side formulation by substituting a
portion of one or more polyols in the reference formulation such
that the --OH number of the B-side formulation for the strengthened
foam is substantially the same as that of the B-side formulation of
the reference foam formulation. In certain embodiments, the method
is characterized in that the density of the strengthened foam
formulation is at least 10% lower than the density of the reference
foam formulation. In certain embodiments, the method is
characterized in that the density of the strengthened foam
formulation is at least 10%, at least 20%, at least 30%, at least
40%, or at least 50%, less than the density of the reference foam.
In certain embodiments, the method is characterized in that the
density of the strengthened foam formulation is at least 10%, at
least 20%, at least 30%, at least 40%, or at least 50%, less than
the density of the reference foam while the tear strength of the
strengthened foam is at least equal to, at least 10% greater than,
at least 20% greater than, at least 30% greater than, at least 40%
greater than, at least 50% greater than, at least 75% greater than,
or at least 100% greater than the tear strength of the reference
foam.
[0103] In certain embodiments, a strengthened foam composition made
by the preceding methods comprises a flexible polyurethane foam. In
certain embodiments, a strengthened foam composition made by the
preceding methods comprises a viscoelastic polyurethane foam. In
certain embodiments, a strengthened foam composition made by the
preceding methods comprises a rigid polyurethane foam.
[0104] In certain embodiments, a polycarbonate polyol utilized in
the methods described above has a primary repeating unit having a
structure:
##STR00004## [0105] where R.sup.1, R.sup.2, R.sup.3, and R.sup.4
are, at each occurrence in the polymer chain, independently
selected from the group consisting of --H, fluorine, an optionally
substituted C.sub.1-40 aliphatic group, an optionally substituted
C.sub.1-20 heteroaliphatic group, and an optionally substituted
aryl group, where any two or more of R.sup.1, R.sup.2, R.sup.3, and
R.sup.4 may optionally be taken together with intervening atoms to
form one or more optionally substituted rings optionally containing
one or more heteroatoms.
[0106] In certain embodiments, the polycarbonate polyols utilized
in the methods described above contain a primary repeating unit
having a structure:
##STR00005## [0107] where R.sup.1 is as defined above.
[0108] In certain embodiments, a polycarbonate polyol utilized in
the methods described above contains a primary repeating unit
having a structure:
##STR00006## [0109] wherein R.sup.1 is, at each occurrence in the
polymer chain, independently --H, or --CH.sub.3.
[0110] In certain embodiments, the polycarbonate polyol utilized in
the methods described above is characterized in that it has a
number average molecular weight (Mn) between about 500 g/mol and
about 20,000 g/mol. In certain embodiments, the polycarbonate
polyol is characterized in that it has an Mn between about 1,000
g/mol and about 5,000 g/mol. In certain embodiments, the
polycarbonate polyol is characterized in that it has an Mn between
about 1,000 g/mol and about 3,000 g/mol. In certain embodiments,
the polycarbonate polyol is characterized in that it has an Mn of
about 1,000 g/mol, about 1,200 g/mol, about 1,500 g/mol, about
2,000 g/mol, about 2,500 g/mol or about 3,000 g/mol.
[0111] In certain embodiments, the polycarbonate polyol utilized in
the methods described above is characterized in that it has a high
percentage of end groups reactive toward isocyanates. In certain
embodiments, more than 98%, more than 99%, more than 99.5%, more
than 99.8%, more than 99.9%, or essentially 100% of the chain ends
are groups reactive toward isocyanates. In certain embodiments, the
chain ends reactive toward isocyanates comprise --OH groups.
[0112] In certain embodiments, aliphatic polycarbonate polyols
utilized in the methods described above are characterized in that
they are substantially compatible with or soluble in the other
polyols present in the polyol component of the foam
formulations.
[0113] Substantially compatible in this context means that the
aliphatic polycarbonate can be mixed with the other polyol or
polyols and provide a mixture that is homogenous or nearly
homogenous. In certain embodiments, the mixture is largely
homogenous at ambient temperature while in other embodiments, the
mixture is homogenous at elevated temperatures (for example the
mixture is homogenous at 30.degree. C., at 40.degree. C., at
80.degree. C., at 100.degree. C. or at 140.degree. C.). In certain
embodiments, the polyol component of the foam formulation
containing the aliphatic polycarbonate polyol is characterized in
that it is a substantially homogenous transparent mixture.
[0114] In certain embodiments, the structure of the aliphatic
polycarbonate polyol used in the methods above is chosen to enhance
its compatibility with other polyols in the polyol component of the
foam formulation. In certain embodiments, a provided aliphatic
polycarbonate polyol is characterized in that it has one or more
ether linkages present in a chain transfer agent embedded within
the polycarbonate chain. In certain embodiments, such ether
linkages derive from the use of diethylene glycol, dipropylene
glycol, triethylene glycol, tripropylene glycol, higher
polyethylene glycols, higher polypropylene glycols, or
polyethylene-co-propylene glycols as chain transfer agents in the
preparation of the aliphatic polycarbonate polyol. In certain
embodiments, such ether linkages are provided by utilizing
ethoxylated or propolxylated diols, triols, or higher polyhydric
alcohols having four or more --OH groups. In certain embodiments,
such ether linkages are provided by utilizing isosorbide, or other
carbohydrate-derived materials as chain transfer agents.
[0115] In certain embodiments, a provided aliphatic polycarbonate
polyol is characterized in that it has a functional number of 2. In
certain embodiments provided aliphatic polycarbonate polyols have a
functional number greater than 2. In certain embodiments provided
aliphatic polycarbonate polyols have a functional number between 2
and 4. In certain embodiments provided aliphatic polycarbonate
polyols have a functional number between 2 and 3. In certain
embodiments provided aliphatic polycarbonate polyols have a
functional number between 2 and about 2.6, between 2 and about 2.5,
or between 2 and about 2.4. In certain embodiments, the provided
aliphatic polycarbonate polyol is characterized in that it
comprises a mixture of diol (functional number 2) with a higher
functional polyol (e.g. a polyol with a functional number of 3, 4,
5, or 6).
[0116] In certain embodiments, a provided aliphatic polycarbonate
polyol is characterized in that it has a number average molecular
weight (Mn) less than about 10,000 g/mol. In certain embodiments, a
provided aliphatic polycarbonate polyol is characterized in that it
has an Mn between 400 and about 10,000 g/mol. In certain
embodiments, a provided aliphatic polycarbonate polyol is
characterized in that it has an Mn between 400 and about 5,000
g/mol, between 500 and about 3,000 g/mol, between 700 and about
2,500 g/mol, between 1,000 and 3,000 g/mol, or between 700 and 1500
g/mol.
[0117] In certain embodiments, a provided aliphatic polycarbonate
polyol is characterized in that it comprises a copolymer of carbon
dioxide and one or both of ethylene oxide and propylene oxide
having an Mn less than 10,000 g/mol, a functional number between 2
and 4, and having one or more ether linkages present in a chain
transfer agent embedded within the polycarbonate chain. In certain
embodiments, a provided polycarbonate polyol comprises comprises
poly(propylene carbonate) containing an embedded chain transfer
agent derived from diethylene glycol, dipropylene glycol,
triethylene glycol, tripropylene glycol, higher polyethylene
glycols, higher polypropylene glycols, polyethylene-co-propylene
glycols, or alkoxylated polyhydric alcohols, characterized in that
it has an Mn less than 5,000 g/mol, and a functional number between
2 and 3. In certain embodiments, a provided polycarbonate polyol
comprises comprises poly(propylene carbonate) containing an
embedded chain transfer agent derived from diethylene glycol,
dipropylene glycol, triethylene glycol, tripropylene glycol, higher
polyethylene glycols, higher polypropylene glycols,
polyethylene-co-propylene glycols, or alkoxylated polyhydric
alcohols, characterized in that it has an Mn less than 3,000 g/mol,
and a functional number between 2 and 2.5. In certain embodiments,
a provided polycarbonate polyol comprises comprises poly(propylene
carbonate) containing an embedded chain transfer agent derived from
diethylene glycol, dipropylene glycol, triethylene glycol,
tripropylene glycol, higher polyethylene glycols, higher
polypropylene glycols, polyethylene-co-propylene glycols, or
alkoxylated polyhydric alcohols, characterized in that it has an Mn
between 500 and 2,500 g/mol, and a functional number between 2 and
2.5.
[0118] In certain embodiments, a provided polycarbonate polyol
comprises poly(ethylene carbonate) containing an embedded chain
transfer agent derived from diethylene glycol, dipropylene glycol,
triethylene glycol, tripropylene glycol, higher polyethylene
glycols, higher polypropylene glycols, polyethylene-co-propylene
glycols, or alkoxylated polyhydric alcohols, characterized in that
it has an Mn less than 5,000 g/mol, and a functional number between
2 and 3. In certain embodiments, a provided polycarbonate polyol
comprises poly(ethylene carbonate) containing an embedded chain
transfer agent derived from diethylene glycol, dipropylene glycol,
triethylene glycol, tripropylene glycol, higher polyethylene
glycols, higher polypropylene glycols, polyethylene-co-propylene
glycols, or alkoxylated polyhydric alcohols, characterized in that
it has an Mn less than 3,000 g/mol, and a functional number between
2 and 2.5. In certain embodiments, a provided polycarbonate polyol
comprises poly(ethylene carbonate) containing an embedded chain
transfer agent derived from diethylene glycol, dipropylene glycol,
triethylene glycol, tripropylene glycol, higher polyethylene
glycols, higher polypropylene glycols, polyethylene-co-propylene
glycols, or alkoxylated polyhydric alcohols, characterized in that
it has an Mn between 500 and 2,500 g/mol, and a functional number
between 2 and 2.5. In certain embodiments, a provided polycarbonate
polyol comprises poly(ethylene-co-propylene carbonate) containing
an embedded chain transfer agent derived from diethylene glycol,
dipropylene glycol, triethylene glycol, tripropylene glycol, higher
polyethylene glycols, higher polypropylene glycols,
polyethylene-co-propylene glycols, or alkoxylated polyhydric
alcohols, characterized in that it has an Mn less than 5,000 g/mol,
and a functional number between 2 and 3. In certain embodiments, a
provided polycarbonate polyol comprises poly(ethylene-co-propylene
carbonate) containing an embedded chain transfer agent derived from
diethylene glycol, dipropylene glycol, triethylene glycol,
tripropylene glycol, higher polyethylene glycols, higher
polypropylene glycols, polyethylene-co-propylene glycols, or
alkoxylated polyhydric alcohols, characterized in that it has an Mn
less than 3,000 g/mol, and a functional number between 2 and 2.5.
In certain embodiments, a provided polycarbonate polyol comprises
poly(ethylene-co-propylene carbonate) containing an embedded chain
transfer agent derived from diethylene glycol, dipropylene glycol,
triethylene glycol, tripropylene glycol, higher polyethylene
glycols, higher polypropylene glycols, polyethylene-co-propylene
glycols, or alkoxylated polyhydric alcohols, characterized in that
it has an Mn between 500 and 2,500 g/mol, and a functional number
between 2 and 2.5.
[0119] The structures and properties of additional aliphatic
polycarbonate polyols that have utility for methods of the present
invention are described in Appendix A at the end of this
specification entitled "Aliphatic Polycarbonate Polyols". In
certain embodiments, the present invention encompasses any of the
methods described above, wherein the added polycarbonate polyol is
selected from any one or more of those described in Appendix A.
[0120] In certain embodiments, methods of the present invention
comprise the additional step of reacting any of the B-side mixtures
containing aliphatic polycarbonate polyols described above with an
A-side formulation comprising one or more polyisocyanates.
[0121] The art of polyurethane synthesis is well advanced and a
very large number of isocyanates and related polyurethane
precursors are known in the art and available commercially. It is
to be understood that it is within the capabilities of one skilled
in the art of polyurethane formulation to use such isocyanates
along with the teachings of this disclosure to practice methods
within the scope of the present invention. Descriptions of suitable
isocyanate compounds and related methods can be found in: Chemistry
and Technology of Polyols for Polyurethanes Ionescu, Mihail 2005
(ISBN 978-1-84735-035-0), and H. Ulrich, "Urethane Polymers,"
Kirk-Othmer Encyclopedia of Chemical Technology, 1997 the entirety
of each of which is incorporated herein by reference. In certain
embodiments, the A-side formulations contain one or more of the
isocyanate reagents described in Appendix B entitled Isocyanate
Reagents appearing at the end of this specification.
[0122] As an alternative to the methods above, another strategy
encompassed by the present invention involves incorporating
aliphatic polycarbonate polyols into a foam formulation by
incorporating them not in the B-side polyol mixture, but as part of
the A-side isocyanate component of the foam. This strategy can
yield the same strength enhancing advantages described hereinabove.
This variation of the invention can be accomplished by utilizing
known methods to manufacture isocyanate terminated prepolymers from
the epoxide CO.sub.2 copolymeric polyols and adding these
isocyanate-terminated materials to the A-side component of the foam
formulation in place of a portion of the polyisocyanate used in a
non-strengthened reference formulation. Methods of converting
polyols to isocyanate-terminated prepolymers by reacting the polyol
with a molar excess of a diisocyanate are well known in the
art.
[0123] In certain embodiments, methods of the present invention
include the step of providing in the polyisocyanate component of a
polyurethane foam composition, a strength enhancing additive
comprising an isocyanate-terminated aliphatic polycarbonate polyol
derived from the copolymerization of CO.sub.2 and one or more
epoxides. Therefore, the invention encompasses all of the
variations and embodiments described above for the production of
high strength polyurethane foam compositions, but modified in that
the step of strengthening the foam comprises the sub-steps of:
[0124] a) reacting a polycarbonate polyol comprising a copolymer of
CO.sub.2 and one or more epoxides with an excess of a
polyisocyanate (or a reactive equivalent thereof), to provide an
isocyanate terminated polycarbonate polyol, and [0125] b) adding
the isocyanate terminated polycarbonate polyol to the isocyanate
component of a foam composition.
[0126] Further variations of the methods described above including
the additional steps necessary to formulate a finished foam will be
readily apparent to the skilled artisan. Therefore, while the
present specification does not describe them, methods including
additional steps typical of foam formulation are specifically
encompassed by the present invention. Such additional steps may
include, but are not limited to: [0127] addition of additional
components to the A- and/or B-side formulations (e.g. catalysts,
blowing agents, pigments, stabilizers, flame retardants, cell
openers, surfactants, reactive diluents, antimicrobials, and the
like); [0128] heating, cooling, mixing or combining the A-side and
B-side components; and [0129] molding, extruding, blowing,
spraying, heating, curing, aging, or otherwise treating the foam
formulation;
II. High Strength Polyurethane Foam Compositions
[0130] In another aspect, the present invention encompasses high
strength polyurethane foam compositions. In certain embodiments,
the inventive compositions possess unexpected combinations of
characteristics including enhanced strength at a given density, or
higher compression force deflection in combination with good
comfort characteristics. These foam compositions satisfy and an
unmet need in the foam industry and it is anticipated that the
compositions will have great value in applications where high
strength or good wearing properties must currently be weighed
against a desire for low density or low cost foams.
[0131] In certain embodiments, the present invention provides a
polyurethane foam composition comprising the reaction product of a
polyol component and a polyisocyanate component, where the polyol
component comprises a polycarbonate polyol derived from the
copolymerization of one or more epoxides and carbon dioxide. In
certain embodiments, the polycarbonate polyol is present in a
quantity from about 1 weight percent to about 50 weight percent of
all polyols present in the polyol component. In certain
embodiments, the foam compositions are characterized in that their
load bearing properties are higher than corresponding foams
formulated without the polycarbonate polyol.
[0132] In certain embodiments, foam compositions of the present
invention comprise the reaction product of a polyol component and a
polyisocyanate component, where the polyol component contains a
polycarbonate polyol derived from the copolymerization of one or
more epoxides and carbon dioxide. In certain embodiments, the
polycarbonate polyol is present in a quantity from about 1 weight
percent to about 50 weight percent of all polyols present in the
polyol component of the foam formulation. In certain embodiments,
the polycarbonate polyol is present in a quantity from about 2
weight percent to about 50 weight percent of all polyols present in
the polyol component of the foam formulation. In certain
embodiments, the polycarbonate polyol is present in a quantity from
about 5 weight percent, to about 25 weight percent of all polyol
present in the polyol component. In certain embodiments, the
polycarbonate polyol is present in a quantity from about 1 weight
percent to about 2 weight percent of all polyol present in the
polyol component. In certain embodiments, the polycarbonate polyol
is present in a quantity from about 2 weight percent to about 5
weight percent of all polyol present in the polyol component. In
certain embodiments, the polycarbonate polyol is present in a
quantity from about 2 weight percent to about 10 weight percent of
all polyol present in the polyol component. In certain embodiments,
the polycarbonate polyol is present in a quantity from about 5
weight percent to about 10 weight percent of all polyol present in
the polyol component. In certain embodiments, the polycarbonate
polyol is present in a quantity from about 10 weight percent, to
about 20 weight percent of all polyol present in the polyol
component. In certain embodiments, the polycarbonate polyol is
present in a quantity from about 20 weight percent, to about 30
weight percent of all polyol present in the polyol component. In
certain embodiments, the polycarbonate polyol is present in a
quantity from about 30 weight percent, to about 50 weight percent
of all polyol present in the polyol component. In certain
embodiments, the polycarbonate polyol is present in a quantity of
about 1 weight percent of all polyol present in the polyol
component. In certain embodiments, the polycarbonate polyol is
present in a quantity of about 1 weight percent of all polyol
present in the polyol component. In certain embodiments, the
polycarbonate polyol is present in a quantity of about 2 weight
percent of all polyol present in the polyol component. In certain
embodiments, the polycarbonate polyol is present in a quantity of
about 3 weight percent of all polyol present in the polyol
component. In certain embodiments, the polycarbonate polyol is
present in a quantity of about 5 weight percent of all polyol
present in the polyol component. In certain embodiments, the
polycarbonate polyol is present in a quantity of about 10 weight
percent of all polyol present in the polyol component. In certain
embodiments, the polycarbonate polyol is present in a quantity of
about 15 weight percent of all polyol present in the polyol
component. In certain embodiments, the polycarbonate polyol is
present in a quantity of about 20 weight percent of all polyol
present in the polyol component. In certain embodiments, the
polycarbonate polyol is present in a quantity of about 25 weight
percent of all polyol present in the polyol component. In certain
embodiments, the polycarbonate polyol is present in a quantity of
about 30 weight percent of all polyol present in the polyol
component. In certain embodiments, the polycarbonate polyol is
present in a quantity of about 40 weight percent of all polyol
present in the polyol component. In certain embodiments, the
polycarbonate polyol is present in a quantity of about 50 weight
percent of all polyol present in the polyol component.
[0133] In certain embodiments, the other polyols present in the
polyol component (i.e. the polyols other than the polycarbonate
polyol derived from the copolymerization of one or more epoxides
and carbon dioxide) are selected from the group consisting of:
polyether polyols, polyester polyols, polybutadiene polyols,
polysulfide polyols, natural oil polyols, fluorinated polyols,
aliphatic polyols, polycarbonate polyols other than those derived
from epoxide-CO.sub.2 copolymerization, and mixtures of any two or
more these. In certain embodiments, between about 50 percent and
about 99 percent of the total weight of polyol present in the
polyol component (i.e. exclusive of any other non-polyol components
that may be present in a B-side composition for foams such as
catalysts, cell openers, blowing agents, stabilizers, diluents and
the like) comprises one or more polyols selected from the group
consisting of polyether polyols, polyester polyols, polybutadiene
polyols, polysulfide polyols, natural oil polyols, fluorinated
polyols, aliphatic polyols, polycarbonate polyols other than those
derived from epoxide-CO.sub.2 copolymerization and mixtures of any
two or more these. In certain embodiments, the other polyol present
in the polyol component substantially comprises polyether polyol.
In certain embodiments, the other polyol present in the polyol
component substantially comprises polyester polyol. In certain
embodiments, the other polyols present in the polyol component
substantially comprise a mixture of polyether and polyester
polyols.
[0134] In certain embodiments, a high strength foam composition of
the present invention comprises a polyol having a primary repeating
unit having a structure:
##STR00007## [0135] where R.sup.1, R.sup.2, R.sup.3, and R.sup.4
are, at each occurrence in the polymer chain, independently
selected from the group consisting of --H, fluorine, an optionally
substituted C.sub.1-40 aliphatic group, an optionally substituted
C.sub.1-20 heteroaliphatic group, and an optionally substituted
aryl group, where any two or more of R.sup.1, R.sup.2, R.sup.3, and
R.sup.4 may optionally be taken together with intervening atoms to
form one or more optionally substituted rings optionally containing
one or more heteroatoms.
[0136] In certain embodiments, a high strength foam composition of
the present invention comprises a polyol having a primary repeating
unit having a structure:
##STR00008## [0137] where R.sup.1 is as defined above.
[0138] In certain embodiments, a high strength foam composition of
the present invention comprises a polyol having a primary repeating
unit having a structure:
##STR00009## [0139] wherein R.sup.1 is, at each occurrence in the
polymer chain, independently --H, or --CH.sub.3.
[0140] In certain embodiments, the high strength foam compositions
described above are characterized in that the polycarbonate polyol
derived from the copolymerization of one or more epoxides and
carbon dioxide has a number average molecular weight (Mn) between
about 500 g/mol and about 20,000 g/mol. In certain embodiments, the
polycarbonate polyol has an Mn between about 1,000 g/mol and about
5,000 g/mol. In certain embodiments, the polycarbonate polyol has
an Mn between about 1,000 g/mol and about 3,000 g/mol. In certain
embodiments, the polycarbonate polyol has an Mn of about 1,000
g/mol, about 1,200 g/mol, about 1,500 g/mol, about 2,000 g/mol,
about 2,500 g/mol or about 3,000 g/mol.
[0141] In certain embodiments, the high strength foam compositions
described above are characterized in that the polycarbonate polyol
incorporated as an additive has a high percentage of end groups
reactive toward isocyanates. In certain embodiments, more than 98%,
more than 99%, more than 99.5%, more than 99.8%, more than 99.9%,
or essentially 100%/c of the polycarbonate polyol chain ends are
groups reactive toward isocyanates. In certain embodiments, the
chain ends reactive toward isocyanates comprise --OH groups.
[0142] In certain embodiments, the high strength foam compositions
described above are characterized in that the polycarbonate polyols
incorporated as additives are substantially compatible with or
soluble in other polyols present in the polyol component of the
foam formulations. Substantially compatible in this context means
that the aliphatic polycarbonate can be mixed with the other polyol
or polyols and provide a mixture that is homogenous or nearly
homogenous. In certain embodiments, the mixture is largely
homogenous at ambient temperature while in other embodiments, the
mixture is homogenous at elevated temperatures (for example the
mixture is homogenous at 30.degree. C., at 40.degree. C., at
80.degree. C., at 100.degree. C. or at 140.degree. C.). In certain
embodiments, the polyol component of the foam formulation
containing the aliphatic polycarbonate polyol is a substantially
homogenous transparent mixture.
[0143] In certain embodiments, the high strength foam compositions
of the present invention are characterized in that the structure of
the aliphatic polycarbonate polyol incorporated is chosen to
enhance its compatibility with other polyols in the polyol
component of the foam formulation. In certain embodiments, the
aliphatic polycarbonate polyol is characterized in that it has one
or more ether linkages present in a chain transfer agent embedded
within the polycarbonate chain. In certain embodiments, such ether
linkages derive from the use of diethylene glycol, dipropylene
glycol, triethylene glycol, tripropylene glycol, higher
polyethylene glycols, higher polypropylene glycols, or
polyethylene-co-propylene glycols as chain transfer agents in the
preparation of the aliphatic polycarbonate polyol. In certain
embodiments, such ether linkages are provided by utilizing
ethoxylated or propolxylated diols, triols, or higher polyhydric
alcohols having four or more --OH groups. In certain embodiments,
such ether linkages are provided by utilizing isosorbide, or other
carbohydrate-derived materials as chain transfer agents.
[0144] In certain embodiments, the high strength foam compositions
of the present invention are characterized in that the aliphatic
polycarbonate polyol used in the compositions has a functional
number of 2 or about 2. In certain embodiments the aliphatic
polycarbonate polyols have a functional number greater than 2. In
certain embodiments the aliphatic polycarbonate polyols have a
functional number between 2 and 4. In certain embodiments the
aliphatic polycarbonate polyols have a functional number between 2
and 3. In certain embodiments the aliphatic polycarbonate polyols
have a functional number between 2 and about 2.6, between 2 and
about 2.5, or between 2 and about 2.4. In certain embodiments, the
aliphatic polycarbonate polyol is characterized in that it
comprises a mixture of diol (functional number 2) with one or more
higher functional polyols (e.g. a polyol with a functional number
of 3, 4, 5, or 6).
[0145] In certain embodiments, the high strength foam compositions
of the present invention are characterized in that they incorporate
an aliphatic polycarbonate polyol having a number average molecular
weight (Mn) less than about 10,000 g/mol. In certain embodiments,
the incorporated aliphatic polycarbonate polyols have Mn between
400 and about 10,000 g/mol. In certain embodiments, the
incorporated aliphatic polycarbonate polyols are characterized in
that they have an Mn between 400 and about 5,000 g/mol, between 500
and about 3,000 g/mol, between 700 and about 2,500 g/mol, between
1,000 and 3,000 g/mol, or between 700 and 1500 g/mol.
[0146] In certain embodiments, the high strength foam compositions
of the present invention are characterized in that they incorporate
a copolymer of carbon dioxide and one or both of ethylene oxide and
propylene oxide having an Mn less than 10,000 g/mol, a functional
number between 2 and 4, and having one or more ether linkages
present in a chain transfer agent embedded within the polycarbonate
chain. In certain embodiments, the incorporated polycarbonate
polyol comprises comprises poly(propylene carbonate) containing an
embedded chain transfer agent derived from diethylene glycol,
dipropylene glycol, triethylene glycol, tripropylene glycol, higher
polyethylene glycols, higher polypropylene glycols,
polyethylene-co-propylene glycols, or alkoxylated polyhydric
alcohols, characterized in that it has an Mn less than 5,000 g/mol,
and a functional number between 2 and 3. In certain embodiments,
the incorporated polycarbonate polyol comprises poly(propylene
carbonate) containing an embedded chain transfer agent derived from
diethylene glycol, dipropylene glycol, triethylene glycol,
tripropylene glycol, higher polyethylene glycols, higher
polypropylene glycols, polyethylene-co-propylene glycols, or
alkoxylated polyhydric alcohols, characterized in that it has an Mn
less than 3,000 g/mol, and a functional number between 2 and 2.5.
In certain embodiments, the incorporated polycarbonate polyol
comprises poly(propylene carbonate) containing an embedded chain
transfer agent derived from diethylene glycol, dipropylene glycol,
triethylene glycol, tripropylene glycol, higher polyethylene
glycols, higher polypropylene glycols, polyethylene-co-propylene
glycols, or alkoxylated polyhydric alcohols, characterized in that
it has an Mn between 500 and 2,500 g/mol, and a functional number
between 2 and 2.5.
[0147] In certain embodiments, the incorporated polycarbonate
polyol comprises poly(ethylene carbonate) containing an embedded
chain transfer agent derived from diethylene glycol, dipropylene
glycol, triethylene glycol, tripropylene glycol, higher
polyethylene glycols, higher polypropylene glycols,
polyethylene-co-propylene glycols, or alkoxylated polyhydric
alcohols, characterized in that it has an Mn less than 5,000 g/mol,
and a functional number between 2 and 3. In certain embodiments,
the incorporated polycarbonate polyol comprises comprises
poly(ethylene carbonate) containing an embedded chain transfer
agent derived from diethylene glycol, dipropylene glycol,
triethylene glycol, tripropylene glycol, higher polyethylene
glycols, higher polypropylene glycols, polyethylene-co-propylene
glycols, or alkoxylated polyhydric alcohols, characterized in that
it has an Mn less than 3,000 g/mol, and a functional number between
2 and 2.5. In certain embodiments, the incorporated polycarbonate
polyol comprises poly(ethylene carbonate) containing an embedded
chain transfer agent derived from diethylene glycol, dipropylene
glycol, triethylene glycol, tripropylene glycol, higher
polyethylene glycols, higher polypropylene glycols,
polyethylene-co-propylene glycols, or alkoxylated polyhydric
alcohols, characterized in that it has an Mn between 500 and 2,500
g/mol, and a functional number between 2 and 2.5.
[0148] In certain embodiments, a provided polycarbonate polyol
comprises poly(ethylene-co-propylene carbonate) containing an
embedded chain transfer agent derived from diethylene glycol,
dipropylene glycol, triethylene glycol, tripropylene glycol, higher
polyethylene glycols, higher polypropylene glycols,
polyethylene-co-propylene glycols, or alkoxylated polyhydric
alcohols, characterized in that it has an Mn less than 5,000 g/mol,
and a functional number between 2 and 3. In certain embodiments,
the incorporated polycarbonate polyol comprises
poly(ethylene-co-propylene carbonate) containing an embedded chain
transfer agent derived from diethylene glycol, dipropylene glycol,
triethylene glycol, tripropylene glycol, higher polyethylene
glycols, higher polypropylene glycols, polyethylene-co-propylene
glycols, or alkoxylated polyhydric alcohols, characterized in that
it has an Mn less than 3,000 g/mol, and a functional number between
2 and 2.5. In certain embodiments, the incorporated polycarbonate
polyol comprises poly(ethylene-co-propylene carbonate) containing
an embedded chain transfer agent derived from diethylene glycol,
dipropylene glycol, triethylene glycol, tripropylene glycol, higher
polyethylene glycols, higher polypropylene glycols,
polyethylene-co-propylene glycols, or alkoxylated polyhydric
alcohols, characterized in that it has an Mn between 500 and 2,500
g/mol, and a functional number between 2 and 2.5.
[0149] The structures and properties of aliphatic polycarbonate
polyols that may be incorporated in the high strength foam
compositions of the present invention are more fully described in
Appendix A at the end of this specification entitled "Aliphatic
Polycarbonate Polyols". In certain embodiments, the present
invention encompasses any of the foam formulations described above,
wherein the polycarbonate polyol used in their formulation is
selected from any one or more of those described in Appendix A.
[0150] High strength foam compositions of the present invention
comprise the reaction product of any of the B-side mixtures
containing aliphatic polycarbonate polyols described above with an
A-side formulation comprising one or more polyisocyanates. In
certain embodiments, the high strength foam compositions of the
present invention comprise MDI-based polyurethane foams. In certain
embodiments, the high strength foam compositions of the present
invention comprise TDI-based polyurethane foams.
[0151] The art of polyurethane synthesis is well advanced and a
very large number of isocyanates and related polyurethane
precursors are known in the art and available commercially. It is
to be understood that it is within the capabilities of one skilled
in the art of polyurethane formulation to select and use such
isocyanates along with the teachings of this disclosure to produce
high strength foams within the scope of the present invention.
Descriptions of suitable isocyanate compounds and analogs can be
found in: Chemistry and Technology of Polyols for Polyurethanes
Ionescu, Mihail 2005 (ISBN 978-1-84735-035-0), and H. Ulrich,
"Urethane Polymers," Kirk-Othmer Encyclopedia of Chemical
Technology, 1997 the entirety of each of which is incorporated
herein by reference. In certain embodiments, the inventive foams
comprise the reaction product of any of the polyol formulations
described above with A-side formulations containing one or more of
the isocyanate reagents described in Appendix B entitled Isocyanate
Reagents appearing at the end of this specification.
[0152] In certain embodiments, a high strength foam composition of
the present invention comprises a flexible polyurethane foam. In
certain embodiments, a high strength foam composition of the
present invention comprises a viscoelastic polyurethane foam. In
certain embodiments, a high strength foam composition of the
present invention comprises a rigid polyurethane foam.
[0153] In certain embodiments, the inventive high strength foams
described above comprise flexible foam compositions. In certain
embodiments, the inventive high strength foams described above high
resilience flexible foam compositions. In certain embodiments, the
present invention provides articles manufactured from such flexible
foam compositions. Such articles include, but are not limited to:
slabstock foams, seating cushions for residential and office use,
mattresses, personal protective gear, athletic equipment, office
furniture, transportation seating, automotive interior components
and surfaces such as dash boards, door panels, headliners and the
like.
A. Flexible Foam Compositions
[0154] In certain embodiments, compositions of the present
invention comprise high strength flexible polyurethane foam
compositions derived from a B-side composition comprising a
polyether polyol in combination with a polycarbonate polyol derived
from the copolymerization of one or more epoxides and carbon
dioxide. In certain embodiments the polycarbonate polyol is present
in such a quantity that the final B-side composition contains from
about 1 part to about 100 parts by weight of polycarbonate polyol
based on 100 parts of polyether polyol. In certain embodiments, the
polycarbonate polyol is present in such a quantity that the
polycarbonate polyol comprises about 5 parts, about 10 parts, about
20 parts, about 30 parts, about 40 parts, about 60 parts, about 80
parts, or about 100 parts, based on 100 parts of polyether polyol
in the resulting B-side formulation. In certain embodiments, the
aliphatic polycarbonate polyol comprises poly(propylene carbonate).
In certain embodiments, the aliphatic polycarbonate polyol present
comprises poly(ethylene carbonate). In certain embodiments, the
aliphatic polycarbonate polyol present comprises
poly(ethylene-co-propylene carbonate).
[0155] In certain embodiments, high strength flexible foam
compositions of the present invention are characterized in that
foams have higher strength than corresponding foams formulated
without the polycarbonate polyol. In certain embodiments, the
inventive foams are characterized in that one or more properties
selected from the group consisting of: Tensile Strength at Break
(as measured by ASTM D3574-08 Test E); Tear Strength (as measured
by ASTM D3574-08 Test F); Compression Force Deflection (CFD) (as
measured by ASTM D3574-08 Test C); and Tensile strength and
Elongation after Dry Heat Aging for 22 hours at 140.degree. C. (as
measured by ASTM D3574-08Test K) are enhanced relative to those of
a corresponding reference foam formulated without the polycarbonate
polyol additive.
[0156] In certain embodiments, the present invention provides high
strength flexible polyurethane foam compositions (denoted the
strengthened foam formulation) comprising a polycarbonate polyol
derived from the copolymerization of one or more epoxides and
carbon dioxide and characterized in that the load bearing capacity
of the strengthened foam as indicated by its compression force
deflection (CFD) value measured using ASTM D3574-08 Test C, is
greater than the CFD value of the corresponding foam composition
formulated without the added polycarbonate polyol (denoted the
reference foam formulation). In certain embodiments, the aliphatic
polycarbonate polyol is present in the B-side formulation in place
of a portion of one or more polyols in the reference. Preferably,
this is achieved such that the --OH number of the B-side
formulation for the strengthened foam is substantially the same as
that of the B-side formulation of the reference foam formulation.
In certain embodiments, the inventive high strength foam is
characterized in that the CFD value of the strengthened foam is at
least 10% greater than the CFD value of the reference foam
formulation. In certain embodiments, the high strength foam is
characterized in that the CFD value of the strengthened foam is at
least 10% greater, at least 20% greater, at least 30% greater, at
least 40% greater, at least 50% greater, or at least 100% greater
than the CFD value of the reference foam. In certain embodiments,
the CFD values of the strengthened foam and the reference foam are
normalized for the density of the foam prior to comparing them. In
certain embodiments foam compositions of the present invention are
characterized in that they have substantially the same density as
the reference foam composition to which they are compared.
[0157] In certain embodiments, the present invention provides high
strength flexible polyurethane foam compositions (denoted the
strengthened foam formulation) containing an additive comprising a
polycarbonate polyol derived from the copolymerization of one or
more epoxides and carbon dioxide and characterized in that the
strengthened foam formulation has a lower density than the
corresponding foam composition formulated without the additive
(denoted the reference foam formulation) further characterized in
that the load bearing properties (CFD) of the strengthened foam as
determined by ASTM D3574-08 Test C, are equal to or greater than
those of the reference foam. In certain embodiments, the
composition is characterized in that the additive is provided in
the B-side formulation from which the foam is produced by
substituting a portion of one or more polyols in the reference
formulation such that the --OH number of the B-side formulation for
the strengthened foam is substantially the same as that of the
B-side formulation of the reference foam formulation. In certain
embodiments, the inventive polyurethane foam composition is
characterized in that the density of the strengthened foam
formulation is at least 10% lower than the density of the reference
foam formulation. In certain embodiments, the inventive strength
polyurethane foam composition is characterized in that the density
of the strengthened foam formulation is at least 10%, at least 20%,
at least 30%, at least 40%, or at least 50%, less than the density
of the reference foam. In certain embodiments, the inventive foam
composition is characterized in that its density is at least 10%,
at least 20%, at least 30%, at least 40%, or at least 50%, less
than the density of the reference foam while the CFD of the
strengthened foam is at least equal to, at least 10% greater than,
at least 20% greater than, at least 30% greater than, at least 40%
greater than, at least 50% greater than, at least 75% greater than,
or at least 100% greater than the CFD of the reference foam.
[0158] In certain embodiments, the present invention provides high
strength flexible TDI-based polyurethane foam compositions having
the combination of a density of less than about 2.6 pounds/cubic
foot (pcf) and a CFD as measured by ASTM D3574-08 Test C of at
least 0.4 psi at 25% deflection. In certain embodiments, the method
is characterized in that the CFD value is at least 0.45 psi at 25%
deflection, at least 0.5 psi at 25% deflection, or at least 0.52
psi at 25% deflection. In certain embodiments, the high strength
flexible TDI-based polyurethane foam is characterized in that the
CFD value of the foam measured by ASTM D3574-08 Test C is at least
0.5 psi at 50% deflection. In certain embodiments, high strength
flexible TDI-based polyurethane foam is characterized in that the
CFD value of the strengthened foam measured by ASTM D3574-08 Test C
is at least 0.55 psi at 50% deflection, at least 0.60 psi at 50%/0
deflection, at least 0.65 psi at 50% deflection, at least 0.7 psi
at 50% deflection, or at least 0.75 psi at 50% deflection. In
certain embodiments, the high strength flexible TDI-based
polyurethane foam is characterized in that the CFD value of the
foam measured by ASTM D3574-08 Test C is at least 0.7 psi at 65%
deflection. In certain embodiments, high strength flexible
TDI-based polyurethane foam is characterized in that the CFD value
of the strengthened foam measured by ASTM D3574-08 Test C is at
least 0.75 psi at 65% deflection, at least 0.80 psi at 65%
deflection, at least 0.85 psi at 65% deflection, at least 0.9 psi
at 65% deflection, or at least 1 psi at 65% deflection. In certain
embodiments, the CFD values above are for a foam composition having
a density of between about 2 and 2.6 pcf. In certain embodiments,
the high strength flexible TDI-based polyurethane foam has a
density of between about 2.2 and 2.6 pcf, or a density of about 2.4
pcf. In certain embodiments, the high strength flexible TDI-based
polyurethane foam has a density between about 2 and 2.6 pcf and is
further characterized in that it contains less than 10%/filled
polyol, less than 5% filled polyol, less than 3% filled polyol,
less than 2% filled polyol, less than 1% filled polyol, or
characterized in that it is substantially free of filled polyol. In
certain embodiments, the foam formulations above are characterized
in that they have comfort properties suitable for use in seating
foams.
[0159] In certain embodiments, the present invention provides high
strength flexible TDI-based polyurethane foam compositions having
the combination of a density of less than about 4 pcf and a CFD as
measured by ASTM D3574-08 Test C of at least 0.8 psi at 25%
deflection. In certain embodiments, the method is characterized in
that the CFD value of the strengthened foam formulation is at least
0.85 psi at 25% deflection, at least 0.9 psi at 25% deflection, at
least 0.95 psi at 25% deflection, or at least 1 psi at 25%
deflection. In certain embodiments, the method is characterized in
that the CFD value of the strengthened foam with a density of less
than about 4 pcf as measured by ASTM D3574-08 Test C is at least 1
psi at 50% deflection. In certain embodiments, the high strength
foam composition is characterized in that its CFD value is at least
1.1 psi at 50% deflection, at least 1.15 psi at 50% deflection, at
least 1.2 psi at 50% deflection, at least 1.3 psi at 50%
deflection, or at least 1.4 psi at 50% deflection.
[0160] In certain embodiments, the high strength TDI-based foam
composition is characterized in that the foam has a combination of
a density of less than about 4 pcf and a CFD as measured by ASTM
D3574-08 Test C of at least 1.4 psi at 65% deflection. In certain
embodiments, the high strength foam composition is characterized in
that the CFD value of the foam is at least 1.5 psi at 65%
deflection, at least 1.6 psi at 65% deflection, at least 1.7 psi at
65% deflection, at least 1.8 psi at 65% deflection, at least 1.9
psi at 65% deflection, or at least 2 psi at 65% deflection. In
certain embodiments, the high strength TDI-based foam composition
has a density of between about 3.2 and 3.8 pcf. In certain
embodiments, the high strength TDI-based foam composition has a
density of between about 3.3 and 3.7 pcf, or a density of about 3.5
pcf. In certain embodiments, the high strength TDI-based foam
composition has a density between about 3.2 and 3.8 pcf and is
further characterized in that it contains less than 10% filled
polyol, less than 5% filled polyol, less than 3% filled polyol,
less than 2% filled polyol, less than 1% filled polyol, or
characterized in that it is substantially free of filled polyol. In
certain embodiments, the foam formulations above are characterized
in that they have comfort properties suitable for use in seating
foams.
[0161] In certain embodiments, the present invention provides high
strength flexible MDI-based polyurethane foam compositions having
the combination of a density of less than about 2.5 pounds/cubic
foot (pcf) and a CFD as measured by ASTM D3574-08 Test C of at
least 0.35 psi at 25% deflection. In certain embodiments, the
method is characterized in that the CFD value is at least 0.4 psi
at 25% deflection, at least 0.45 psi at 25% deflection, or at least
0.5 psi at 25% deflection. In certain embodiments, the high
strength flexible MDI-based polyurethane foam is characterized in
that the CFD value of the foam measured by ASTM D3574-08 Test C is
at least 0.4 psi at 50% deflection. In certain embodiments, high
strength flexible MDI-based polyurethane foam is characterized in
that the CFD value of the strengthened foam measured by ASTM
D3574-08 Test C is at least 0.45 psi at 50% deflection, at least
0.50 psi at 50% deflection, at least 0.55 psi at 50% deflection, at
least 0.6 psi at 50% deflection, or at least 0.65 psi at 50%
deflection. In certain embodiments, the high strength flexible
MDI-based polyurethane foam is characterized in that the CFD value
of the foam measured by ASTM D3574-08 Test C is at least 0.7 psi at
65% deflection. In certain embodiments, high strength flexible
MDI-based polyurethane foam is characterized in that the CFD value
of the strengthened foam measured by ASTM D3574-08 Test C is at
least 0.75 psi at 65% deflection, at least 0.80 psi at 65%
deflection, at least 0.85 psi at 65% deflection, at least 0.9 psi
at 65% deflection, or at least 1 psi at 65% deflection. In certain
embodiments, the high strength MDI-based foams have a density of
between about 2 and 2.6 pcf. In certain embodiments the high
strength MDI-based foams have a density of between about 2.2 and
2.6 pcf, or a density of about 2.4 pcf. In certain embodiments, the
high strength MDI-based foams have a density between about 2 and
2.6 pcf and are further characterized in that they contain less
than 10% filled polyol, less than 5% filled polyol, less than 3%
filled polyol, less than 2% filled polyol, less than 1% filled
polyol, or are characterized in that they are substantially free of
filled polyol. In certain embodiments, the foam formulations above
are characterized in that they have comfort properties suitable for
use in seating foams.
[0162] In certain embodiments, the present invention provides high
strength flexible MDI-based polyurethane foam compositions having
the combination of a density of less than about 4 pcf and a CFD as
measured by ASTM D3574-08 Test C of at least 0.8 psi at 25%
deflection. In certain embodiments, the method is characterized in
that the CFD value of the strengthened foam formulation is at least
0.85 psi at 25% deflection, at least 0.9 psi at 25% deflection, at
least 0.95 psi at 25% deflection, or at least 1 psi at 25%
deflection. In certain embodiments, the method is characterized in
that the CFD value of the strengthened foam with a density of less
than about 4 pcf as measured by ASTM D3574-08 Test C is at least 1
psi at 50% deflection. In certain embodiments, the high strength
foam composition is characterized in that its CFD value is at least
1.1 psi at 50% deflection, at least 1.2 psi at 50% deflection, at
least 1.4 psi at 50% deflection, at least 1.5 psi at 50%
deflection, or at least 1.8 psi at 50% deflection.
[0163] In certain embodiments, the high strength MDI-based foam
composition is characterized in that the foam has a combination of
a density of less than about 4 pcf and a CFD as measured by ASTM
D3574-08 Test C of at least 1.4 psi at 65% deflection. In certain
embodiments, the high strength foam composition is characterized in
that the CFD value of the foam is at least 1.5 psi at 65%
deflection, at least 1.6 psi at 65% deflection, at least 1.7 psi at
65% deflection, at least 1.8 psi at 65% deflection, at least 1.9
psi at 65% deflection, at least 2 psi at 65% deflection, or at
least 3 psi at 65% deflection. In certain embodiments, the high
strength MDI-based foam composition has a density of between about
3.2 and 3.8 pcf. In certain embodiments, the high strength
MDT-based foam composition has a density of between about 3.3 and
3.7 pcf, or a density of about 3.5 pcf.
[0164] In certain embodiments, the high strength MDI-based foam
composition has a density between about 3.2 and 3.8 pcf and is
further characterized in that it contains less than 10% filled
polyol, less than 5% filled polyol, less than 3% filled polyol,
less than 2% filled polyol, less than 1% filled polyol, or
characterized in that it is substantially free of filled polyol. In
certain embodiments, the foam formulations above are characterized
in that they have comfort properties suitable for use in seating
foams.
[0165] In certain embodiments, the present invention provides high
strength flexible polyurethane foam compositions (denoted the
strengthened foam formulation) containing an additive comprising a
polycarbonate polyol derived from the copolymerization of one or
more epoxides and carbon dioxide, and characterized in that the
tensile strength of the strengthened foam as measured by ASTM D
3574-08 Test E, is greater than the tensile strength of a
corresponding foam composition formulated without the added
polycarbonate polyol (denoted the reference foam formulation). In
certain embodiments, the aliphatic polycarbonate polyol is present
in the B-side formulation in place of a portion of one or more
polyols in the reference. Preferably, this is achieved such that
the --OH number of the B-side formulation for the strengthened foam
is substantially the same as that of the B-side formulation of the
reference foam formulation. In certain embodiments, the inventive
high strength foam is characterized in that the tensile strength of
the strengthened foam is at least 10% greater than the tensile
strength of the reference foam formulation. In certain embodiments,
the high strength foam is characterized in that the tensile
strength of the strengthened foam is at least 10% greater, at least
20% greater, at least 30% greater, at least 40% greater, at least
50% greater, or at least 100% greater than the tensile strength of
the reference foam. In certain embodiments, the tensile strengths
of the strengthened foam and the reference foam are normalized for
the density of the foam prior to comparing them. In certain
embodiments foam compositions of the present invention are
characterized in that they have substantially the same density as
the reference foam composition to which they are compared.
[0166] In certain embodiments, the present invention provides high
strength flexible polyurethane foam compositions containing an
additive comprising a polycarbonate polyol derived from the
copolymerization of one or more epoxides and carbon dioxide. In
certain embodiments, the inventive foam compositions are
characterized in that they have a lower density than a
corresponding foam composition formulated without the polycarbonate
polyol additive (denoted the reference foam formulation) and
further characterized in that the tensile strength of the
strengthened foam as determined by ASTM D3574-08 Test E is equal to
or greater than that of the reference foam. In certain embodiments,
the composition is characterized in that the additive is provided
in the B-side formulation from which the foam is produced by
substituting a portion of one or more polyols in the reference
formulation such that the --OH number of the B-side formulation for
the strengthened foam is substantially the same as that of the
B-side formulation of the reference foam formulation. In certain
embodiments, the inventive polyurethane foam composition is
characterized in that the density of the strengthened foam
formulation is at least 100% lower than the density of the
reference foam formulation. In certain embodiments, the inventive
strength polyurethane foam composition is characterized in that the
density of the strengthened foam formulation is at least 10%, at
least 20%, at least 30%, at least 40%, or at least 50%, less than
the density of the reference foam. In certain embodiments, the
inventive foam composition is characterized in that its density is
at least 10%, at least 20%, at least 30%, at least 40%, or at least
50%, less than the density of the reference foam while the tensile
strength of the strengthened foam is at least equal to, at least
10% greater than, at least 20% greater than, at least 30% greater
than, at least 40% greater than, at least 50% greater than, at
least 75% greater than, or at least 100% greater than the tensile
strength of the reference foam.
[0167] In certain embodiments, the present invention provides high
strength flexible polyurethane foam compositions (denoted the
strengthened foam formulation) containing an additive comprising a
polycarbonate polyol derived from the copolymerization of one or
more epoxides and carbon dioxide, and characterized in that the
tear strength of the strengthened foam as measured by ASTM D
3574-08 Test E, is greater than the tensile strength of a
corresponding foam composition formulated without the added
polycarbonate polyol (denoted the reference foam formulation). In
certain embodiments, the aliphatic polycarbonate polyol is present
in the B-side formulation in place of a portion of one or more
polyols in the reference. Preferably, this is achieved such that
the --OH number of the B-side formulation for the strengthened foam
is substantially the same as that of the B-side formulation of the
reference foam formulation. In certain embodiments, the inventive
high strength foam is characterized in that the tensile strength of
the strengthened foam is at least 10% greater than the tensile
strength of the reference foam formulation. In certain embodiments,
the high strength foam is characterized in that the tensile
strength of the strengthened foam is at least 10% greater, at least
20% greater, at least 30% greater, at least 40% greater, at least
50% greater, or at least 100% greater than the tensile strength of
the reference foam. In certain embodiments, the tensile strengths
of the strengthened foam and the reference foam are normalized for
the density of the foam prior to comparing them. In certain
embodiments foam compositions of the present invention are
characterized in that they have substantially the same density as
the reference foam composition to which they are compared.
[0168] In certain embodiments, the present invention provides high
strength flexible polyurethane foam compositions containing an
additive comprising a polycarbonate polyol derived from the
copolymerization of one or more epoxides and carbon dioxide. In
certain embodiments, the inventive foam compositions are
characterized in that they have a lower density than a
corresponding foam composition formulated without the polycarbonate
polyol additive (denoted the reference foam formulation) and
further characterized in that the tear strength of the strengthened
foam as determined by ASTM D 3574-08 Test F is equal to or greater
than that of the reference foam. In certain embodiments, the
composition is characterized in that the additive is provided in
the B-side formulation from which the foam is produced by
substituting a portion of one or more polyols in the reference
formulation such that the --OH number of the B-side formulation for
the strengthened foam is substantially the same as that of the
B-side formulation of the reference foam formulation. In certain
embodiments, the inventive polyurethane foam composition is
characterized in that the density of the strengthened foam
formulation is at least 10% lower than the density of the reference
foam formulation. In certain embodiments, the inventive strength
polyurethane foam composition is characterized in that the density
of the strengthened foam formulation is at least 10%, at least 20%,
at least 30%, at least 40%, or at least 50%, less than the density
of the reference foam. In certain embodiments, the inventive foam
composition is characterized in that its density is at least 10%,
at least 20%, at least 30%, at least 40%, or at least 50%, less
than the density of the reference foam while the tear strength of
the strengthened foam is at least equal to, at least 10% greater
than, at least 20% greater than, at least 30% greater than, at
least 40% greater than, at least 50% greater than, at least 75%
greater than, or at least 100% greater than the tensile strength of
the reference foam.
B. Viscoelastic Foam Compositions
[0169] Viscoelastic (VE) foams are typically water blown foams
produced using a mixture of low molecular weight hydrophobic
polyols, high molecular weight polyols produced from propylene
oxide and ethylene oxide and short molecular weight chain
extenders. These foams are usually produced at relatively low
isocyanate indexes which facilitate an open cell structure. In
order to balance foaming rate and open cell morphology, polyols
with high levels of hydrophilic oxyethylene groups are used in
preparation of these foams as well as a variety of surfactants. In
order to produce soft (compliant) foams, isocyanates such as TDI or
mixtures of 4,4'- and 2,4'-MDI are typically used in production of
VE foams. Calcium carbonate or other fillers can also be added to
these formulations to increase density (and load bearing
properties) and to reduce tackiness.
[0170] In certain embodiments, the present invention provides novel
VE foams characterized in that at least a portion of one or more of
the polyols in the B-side formulation is replaced with a
polycarbonate polyol derived from copolymerization of CO.sub.2 and
one or more epoxides. In certain embodiments, the VE foam
compositions are further characterized in that they contain less or
no inorganic filler than a comparative foam having similar
viscoelastic properties but lacking the polycarbonate polyol
additive. In certain embodiments the polycarbonate polyol is
present in such a quantity that the final B-side composition
contains from about 1 part to about 100 parts by weight of
polycarbonate polyol based on 100 parts of polyether polyol. In
certain embodiments, the polycarbonate polyol is present in such a
quantity that the polycarbonate polyol comprises about 5 parts,
about 10 parts, about 20 parts, about 30 parts, about 40 parts,
about 60 parts, about 80 parts, or about 100 parts, based on 100
parts of polyether polyol in the resulting B-side formulation. In
certain embodiments, the aliphatic polycarbonate polyol comprises
poly(propylene carbonate). In certain embodiments, the aliphatic
polycarbonate polyol present comprises poly(ethylene carbonate). In
certain embodiments, the aliphatic polycarbonate polyol present
comprises poly(ethylene-co-propylene carbonate).
[0171] In certain embodiments, high strength VE foam compositions
of the present invention are characterized in that foams have
higher strength than corresponding foams formulated without the
polycarbonate polyol additive. In certain embodiments, the
inventive foams are characterized in that one or more properties
selected from the group consisting of: Tensile Strength at Break
(as measured by ASTM D3574-08 Test E); Tear Strength (as measured
by ASTM D3574-08 Test F); Compression Force Deflection (CFD) (as
measured by ASTM D3574-08 Test C); and Tensile strength and
Elongation after Dry Heat Aging for 22 hours at 140.degree. C. (as
measured by ASTM D3574-08Test K) are enhanced relative to those of
a corresponding reference foam formulated without the polycarbonate
polyol additive.
[0172] In certain embodiments, the present invention provides high
strength VE foam compositions (denoted the strengthened foam
formulation) comprising a polycarbonate polyol derived from the
copolymerization of one or more epoxides and carbon dioxide and
characterized in that the load bearing capacity of the strengthened
foam as indicated by its compression force deflection (CFD) value
measured using ASTM D3574-08 Test C, is greater than the CFD value
of a corresponding VE foam composition formulated without the added
polycarbonate polyol (denoted the reference foam formulation). In
certain embodiments, the aliphatic polycarbonate polyol is present
in the B-side formulation in place of a portion of one or more
polyols in the reference foam. Preferably, this is achieved such
that the --OH number of the B-side formulation for the strengthened
foam is substantially the same as that of the B-side formulation of
the reference foam formulation. In certain embodiments, the
inventive high strength foam is characterized in that the CFD value
of the strengthened foam is at least 10% greater than the CFD value
of the reference foam formulation. In certain embodiments, the high
strength foam is characterized in that the CFD value of the
strengthened foam is at least 10% greater, at least 20% greater, at
least 30% greater, at least 40% greater, at least 50% greater, or
at least 100% greater than the CFD value of the reference foam. In
certain embodiments, the CFD values of the strengthened foam and
the reference foam are normalized for the density of the foam prior
to comparing them. In certain embodiments foam compositions of the
present invention are characterized in that they have substantially
the same density as the reference foam composition to which they
are compared.
[0173] In certain embodiments, the present invention provides high
strength VE foam compositions (denoted the strengthened foam
formulation) containing an additive comprising a polycarbonate
polyol derived from the copolymerization of one or more epoxides
and carbon dioxide, and characterized in that the tensile strength
of the strengthened foam as measured by ASTM D 3574-08 Test E, is
greater than the tensile strength of a corresponding foam
composition formulated without the added polycarbonate polyol
(denoted the reference foam formulation). In certain embodiments,
the aliphatic polycarbonate polyol is present in the B-side
formulation in place of a portion of one or more polyols in the
reference. Preferably, this is achieved such that the --OH number
of the B-side formulation for the strengthened foam is
substantially the same as that of the B-side formulation of the
reference foam formulation. In certain embodiments, the inventive
high strength foam is characterized in that the tensile strength of
the strengthened foam is at least 10% greater than the tensile
strength of the reference foam formulation. In certain embodiments,
the high strength foam is characterized in that the tensile
strength of the strengthened foam is at least 10% greater, at least
20% greater, at least 30% greater, at least 40% greater, at least
50% greater, or at least 100% greater than the tensile strength of
the reference foam. In certain embodiments, the tensile strengths
of the strengthened foam and the reference foam are normalized for
the density of the foam prior to comparing them. In certain
embodiments foam compositions of the present invention are
characterized in that they have substantially the same density as
the reference foam composition to which they are compared.
[0174] In certain embodiments, the present invention provides high
strength VE foam compositions (denoted the strengthened foam
formulation) containing an additive comprising a polycarbonate
polyol derived from the copolymerization of one or more epoxides
and carbon dioxide, and characterized in that the tear strength of
the strengthened foam as measured by ASTM D 3574-08 Test E, is
greater than the tensile strength of a corresponding foam
composition formulated without the added polycarbonate polyol
(denoted the reference foam formulation). In certain embodiments,
the aliphatic polycarbonate polyol is present in the B-side
formulation in place of a portion of one or more polyols in the
reference foam. Preferably, this is achieved such that the --OH
number of the B-side formulation for the strengthened foam is
substantially the same as that of the B-side formulation of the
reference foam formulation. In certain embodiments, the inventive
high strength foam is characterized in that the tensile strength of
the strengthened foam is at least 10% greater than the tensile
strength of the reference foam formulation. In certain embodiments,
the high strength foam is characterized in that the tensile
strength of the strengthened foam is at least 10% greater, at least
20% greater, at least 30% greater, at least 40% greater, at least
50% greater, or at least 100% greater than the tensile strength of
the reference foam. In certain embodiments, the tensile strengths
of the strengthened foam and the reference foam are normalized for
the density of the foam prior to comparing them. In certain
embodiments foam compositions of the present invention are
characterized in that they have substantially the same density as
the reference foam composition to which they are compared.
[0175] In certain embodiments, the present invention provides high
strength VE foam compositions (denoted the strengthened foam
formulation) containing an additive comprising a polycarbonate
polyol derived from the copolymerization of one or more epoxides
and carbon dioxide, and characterized in that the energy absorbing
properties of the foam are increased. In certain embodiments this
increase in energy absorption indicated by an increase in
hysteresis loss according to ASTM 3574-08, Hysteresis Procedure B.
In certain embodiments, the hysteresis loss is greater in the
inventive VE foam than that of a corresponding foam composition
formulated without the added polycarbonate polyol (denoted the
reference foam formulation). In certain embodiments, the inventive
high strength foam is characterized in that its hysteresis loss is
at least 10% greater than that of the reference foam formulation.
In certain embodiments, the inventive high strength foam is
characterized in that its hysteresis loss is at least 20% greater,
at least 30% greater, at least 40% greater, at least 50% greater,
or at least 100% greater than the hysteresis loss of the reference
foam under identical conditions.
[0176] In certain embodiments, viscoelastic foam compositions of
the present invention are characterized in that they have a reduced
quantity of inorganic filler.
C. Foams with Novel Physical Properties
[0177] In another aspect, the present invention encompasses foam
compositions having a novel combination of physical properties. In
certain embodiments, the invention provides a flexible polyurethane
foam comprising the reaction product of a B-side mixture
substantially comprising polyether polyol and an A-side mixture
comprising one or more of MDI or TDI characterized in that the foam
has the combination of: [0178] a density less than 40 kg/m.sup.3 by
ASTM D 3574-08, Test A; [0179] a CFD at 65% of greater than 1 psi
(or 3 kPa) by ASTM D 3574-08, Test C; and [0180] a SAG factor of
between 2.0 and 3.0 (obtained from ASTM D 3574-08, Test C by
dividing the CFD @ 65% compression by the CFD at 25%
compression).
[0181] In certain embodiments, the inventive foam is characterized
in that it has the combination of: a density by ASTM D 3574-08,
Test A, of less than 38, less than 36, less than 34, less than 32
or less than 30 kg/m.sup.3 and a CFD by ASTM D 3574-08, Test C
greater than 1.6 psi at 65% and a SAG factor of about 2.
[0182] In certain embodiments, the inventive foam is characterized
in that it has the combination of: A CFD at 65% by ASTM D 3574-08,
Test C of greater than 0.8 psi, greater than 1.0 psi, greater than
1.2 psi, greater than 1.4 psi, or greater than 1.6 psi, greater
than 1.8 psi, or greater than 2 psi, with a density less than 40
kg/m.sup.3, and a comfort factor between 2 and 3.
[0183] In certain embodiments, the inventive foam is characterized
in that it has the combination of: A CFD at 65% by ASTM D 3574-08,
Test C of greater than 1 psi, greater than 1.2 psi, greater than
1.4 psi, greater than 1.5 psi, or greater than 1.75 psi, or greater
than 2 psi; with a density less than 38, less than 36, less than
34, less than 32 or less than 30 kg/m.sup.3 by ASTM D 3574-08, Test
A, and a comfort factor between 2 and 3.
[0184] One approach used in the field of polyurethane foams today
to increase the strength or CFD of flexible foams is the addition
of graft polyols to the B-side formulation. Graft polyols (also
called filled polyols or polymer polyols) contain finely dispersed
styrene-acrylonitrile, acrylonitrile, or polyurea (PHD) polymer
solids chemically grafted to a polyether backbone. They are used to
increase the load-bearing properties of low-density high-resiliency
(HR) foam, as well as to add toughness to microcellular foams and
cast elastomers. However, these materials increase the cost of the
foams and sometimes result in a dimunition of other foam properties
or an increase in the density of the foam, or as mentioned above,
incroduce undesirable VOCs into the finished products. In certain
embodiments, the inventive foams are characterized in that, in
addition to the combinations of physical properties described
above, they contain little or no graft polyol.
[0185] In certain embodiments, the inventive foam compositions
described above are further characterized in that they contain less
than 20% graft-type polyol additives. In certain embodiments, the
inventive foam compositions described above are further
characterized in that they contain less than 10% graft-type polyol
additives. In certain embodiments, the inventive foam compositions
described above are further characterized in that they contain less
than 5% graft-type polyol additives. In certain embodiments, the
inventive seating foam compositions described above are further
characterized in that they contain less than 3% graft-type polyol
additives. In certain embodiments, the inventive seating foam
compositions described above are further characterized in that they
contain less than 2% graft-type polyol additives. In certain
embodiments, the inventive seating foam compositions described
above are further characterized in that they contain less than 1%
graft-type polyol additives. In certain embodiments, the inventive
seating foam composition described above are further characterized
in that they do not contain graft-type polyol additives.
[0186] In certain embodiments, such filled polyols are selected
from: polyurea dispersion polyols (i.e. Poly Harnststoff Dispersion
(PHD) polyols); Polyurethane dispersion polyols (i.e.
Polyisocyanate poly addition polyols (PIPA); Epoxy dispersion
polyols; Aminoplast dispersions, acrylic polyols and the like. They
are used to increase the load-bearing properties of low-density
high-resiliency (HR) foam, as well as add toughness to
microcellular foams and cast elastomers. However, these materials
increase the cost of the foams and sometimes result in a dimunition
of other foam properties such as resilience or an increase in the
density of the foam. In certain embodiments, the inventive foams
are characterized in that in addition to the combinations of
physical properties described above, they contain little or no
filled polyol.
[0187] In certain embodiments, the inventive foam compositions
described above are further characterized in that they contain less
than 5% filled polyol additives. In certain embodiments, the
inventive seating foam compositions described above are further
characterized in that they contain less than 3% filled polyol
additives. In certain embodiments, the inventive seating foam
compositions described above are further characterized in that they
contain less than 2% filled polyol additives. In certain
embodiments, the inventive seating foam compositions described
above are further characterized in that they contain less than 1%
filled polyol additives. In certain embodiments, the inventive
seating foam compositions described above are further characterized
in that they do not contain graft-type, filled, or acrylic polyol
additives.
[0188] While not necessarily explicitly described, further
variations of the foam compositions described above comprising the
additional components typical in the formulation of a finished foam
are encompassed by the present invention. These compositions will
be readily apparent to the skilled artisan based on the teachings
and disclosure herein in combination with common knowledge in the
field of polyurethane foam formulation. Therefore, though the
present specification may not describe them in detail, compositions
comprising additional reaction components or additives in the A-
and/or B-side formulations (e.g. catalysts, blowing agents,
pigments, stabilizers, flame retardants, cell openers, surfactants,
reactive diluents, antimicrobials, solvents, and the like); are
contemplated and encompassed by the present invention. Non-limiting
examples of additives that can be utilized in the A-side and/or
B-side mixtures of the inventive foams are described in Appendix C,
entitled "Additives" appearing at the end of this
specification.
III. Isocyanate-Terminated Prepolymers with Utility as Foam
Additives
[0189] In another aspect, the present invention encompasses
isocyanate-terminated polyols derived by reaction of an excess of a
polyisocyanate with any of the aliphatic polycarbonate polyols
described above. Such compositions can be incorporated into the
A-side formulation of a polyurethane foam formulation to provide
enhanced strength. Scheme 1 shows a representative example how such
materials can be made:
##STR00010## [0190] where the polycarbonate polyol represents any
of those described above, in Appendix A, or in the classes and
subclasses herein, the diisocyanate represents any reagent capable
or reacting with two alcohols to form two urethane linkages, and
where g is 0, or an integer up to about 10.
[0191] Preferably, g is small so that the Mn of the prepolymer
remains relatively low and the material can be dissolved in a
typical polyurethane A-side mixture without making it overly
viscous. In certain embodiments, the average value of g in the
propolymer composition is less than 10, less than 5, less than 4,
less than 3, less than 2, or less than 1.
[0192] Prepolymers of the present invention may also derive from
higher functional polyols and/or higher functional isocyanates
including those described in appendices A and B appended
hereto.
[0193] In another aspenct, the present invention encompasses
comprising the reaction product between an isocyanate component and
a polyol component wherein the isocyanate component comprises from
about 1% to about 20% weight percent of an isocyanate-terminated
prepolymer comprising a polyol derived from the copolymerization of
CO.sub.2 with one or more epoxides.
EXAMPLES
[0194] The present invention is illustrated by the following
examples. It is to be understood that the particular examples,
materials, amounts, and procedures are to be interpreted broadly in
accordance with the scope and spirit of the invention as set forth
herein.
Example 1: High Strength Flexible Foams
[0195] Presented below are the formulations of high strength
flexible polyurethane foams according to the principles of the
present invention. These materials were made using aliphatic
polycarbonate polyol additives as defined herein. Specifically, the
aliphatic polycarbonate polyols hereinafter also referred to as
"Novomer Polyols" used in the formulations below have the following
properties:
TABLE-US-00001 Property 58-103-C 74-276 Acid Value, mg KOH/g 0.28
0.51 Hydroxyl Value, mg KOH/g 119 61.1 Mn (GPC) 1,270 2,213 Mw
(GPC) 1,370 2,443 Polydispersity, Mw/Mn 1.07 1.06 Glass Transition
Temp. (DSC), Tg -5.degree. C. -5.5.degree. C. Viscosity, cPs 4,990
@ 80.degree. C. --
[0196] Polyol 58-103-C is a linear 1270 g/mol poly(propylene
carbonate) polyol initiated with dipolypropylene glycol (a mixture
of isomers) having a PDI of 1.06, greater than 99% --OH end groups
and greater than 99% carbonate linkages (exclusive of the ether
bonds in the dipropylene glycol). This polyol conforms to the
formula:
##STR00011## [0197] where n is, on average in the composition,
approximately 5.6.
[0198] Polyol 74-276 is a linear 2200 g/mol poly(propylene
carbonate) polyol initiated with 425 g/mol polypropylene glycol
(mixture of isomers) having a PDI of 1.06, greater than 99% --OH
end groups and greater than 99% carbonate linkages (exclusive of
the ether bonds in the polypropylene glycol). This polyol conforms
to the formula:
##STR00012## [0199] where k is on average about 6.8, and n is on
average in the composition approximately 8.7.
[0200] The objective of this study was to determine the effect of
CO.sub.2-based poly(propylene-carbonate) diols (PPC diols) as
additives in a model high resilient (HR) flexible polyurethane
foam.
[0201] The effect of these PPC diols on load bearing and other
properties of free-rise and molded flexible foams were evaluated in
comparison to HR flexible foams formulated with and without a
commercial graft polyol.
[0202] Experimental:
[0203] Raw Materials
[0204] A list of raw materials used in this evaluation is shown in
Table 1. All materials were used as received from suppliers
including Novomer polyols.
[0205] In foaming experiments, a formulation targeting high
resilient flexible foams was used as reference. This formulation is
based on Poly-G 85-29 ethylene oxide tipped polyether triol
(polyol). Lumulse POE 26 (ethoxylated glycerol) was used as
reactive cell opener. Diethanol amine was used as a co-catalyst and
cross-linker.
[0206] Preparation and Testing of Foams
[0207] Free rise water-blown foams were prepared with 5%, 10%, 15%,
20%, and 25% Novomer 58-103C and Novomer 74-276 polyols,
respectively, which were compatible with Poly-G 85-29 polyol
(Tables 2-4). All foams were prepared at 90 Isocyanate Index with
Mondur MRS-2, which is a 2,4'-MDI rich isocyanate (Tables 3-5).
[0208] Molded foams were prepared with 10% and 20% Novomer 58-103C.
Reference molded foams were also prepared with and without graft
polyol Speciflex NC-701.
[0209] Free-rise foams were prepared using a standard laboratory
hand-mixing procedure. Foaming profiles, including cream time, gel
time, and rise time were measured on all foams. After the rise
time, the foams were immediately placed in an air-circulating oven
preheated at 80.degree. C. for 30 minutes to complete the cure.
[0210] Molded foams were prepared using an aluminum mold with
12.times.12.times.2 inch dimensions preheated at 69.degree. C.
Demolding time was 4.5 minutes.
[0211] All foams were aged under room conditions for minimum one
week before testing. The following properties were measured
according to ASTM D 3574-08: [0212] Foam Density (Test A) [0213]
Resilience via Ball Rebound (Test H) [0214] Tensile Strength at
Break (Test E) [0215] Elongation at Break (Test E) [0216] Tear
Strength (Test F) [0217] CFD, Compression Force Deflection (Test C)
[0218] Hysteresis (Procedure B--CFD Hysteresis Loss) [0219] Dry
Constant Deflection Compression Set (Test D) [0220] Wet Constant
Deflection Compression Set (Test D & Wet Heat Aging, Test L)
[0221] Tensile strength and Elongation after Dry Heat Aging for 22
hours at 140.degree. C. (Modified Heat Aging Test K)
TABLE-US-00002 [0221] TABLE 1 Materials Designation Type Supplier
POLYOLS Poly-G 85-29 Ethylene oxide caped polyether Arch polyol
(triol) Chemicals Hydroxyl Value = 27.4 mg KOH/g; Eq. wt. =
2047.445 Viscosity @ 25.degree. C. = 1150 cPs Speciflex NC-701
Grafted polyether polyol DOW containing copolymerized styrene and
acrylonitrile Hydroxyl Value = 23.0 mg KOH/g; Eq. wt. = 2439.13
Viscosity @ 25.degree. C. = 5070 mPa s Novomer 58-103-C Novomer
Poly(Propylene Carbonate) NOVOMER Hydroxyl Value = 119 mg KOH/g;
Eq. wt. = 471.43 Acidity Value = 0.28 mg KOH/g Viscosity @
25.degree. C. = 1.25 .times. 10.sup.6 cPs Viscosity @ 80.degree. C.
= 4990 cPs Novomer 74-245 Novomer Poly(Propylene Carbonate) NOVOMER
Hydroxyl Value = 34.8 mg KOH/g; Eq. wt. = 1612.07 Viscosity @
80.degree. C. = 49,650 cPs Novomer 74-266 Novomer Poly(Propylene
Carbonate) NOVOMER Hydroxyl Value = 63 mg KOH/g; Eq. wt. = 890.47
Acidity Value = 0.24 mg KOH/g Viscosity @ 80.degree. C. = 27,240
cPs Novomer 74-276 Novomer Poly(Propylene Carbonate) NOVOMER polyol
initiated with PPG 600 MW Hydroxyl Value = 61.1 mg KOH/g; Acidity
Value = 0.51 mg KOH/g Eq. wt. = 918.47 SURFACTANTS Tegostab B 4690
Polyether/Silicone Oil Mix Evonik Eq. Wt. = 1335.7 CELL OPENER
Lumulse POE 26 Hydroxyl Value = 134.8 mg KOH/g Lambent Eq. Wt. =
416.2 CHAIN EXTENDERS Diethanolamine Diethanolamine (Eq. Wt. =
35.04) Aldrich CATALYSTS Dabco 33LV 33% Triethylene Air Products
diamine in dipropylene glycol Niax A1 bis(2-dimethylaminoethyl)
ether Momentive ISOCYANATES Mondur MRS-2 2,4' rich diphenylmethane
Bayer diisocyanate (F = 2.2; Eq. wt. = 130.03; % NCO = 32.30%)
[0222] Results
[0223] Polyol Reactivity
[0224] Polyurethane foams were prepared at 5%, 10%, 15%, 20% and
25% as replacement for conventional polyol Poly-G 85-29 in model HR
flexible foam formulation. Introduction of PPC polyol 58-103-C
polyol into reference foam formulation as drop-in replacement for
Poly-G 85-29 did not significantly affect the reaction profile
(foaming profile) measured as cream time, gel time, and rise time.
However, foams exhibited closed cell structure and shrank after
preparation (Table 3A). Stable foams with open cell structure were
obtained after adjustment in catalysis and after increasing the
amount of diethanolamine (reactive catalyst/cross-linker) from 1 to
2 parts by weight (Tables 3A and 3B).
[0225] Foams based on PPC polyol 74-276 polyol were prepared using
the same catalytic package as that used for foams based on Novomer
58-103C polyol. No significant difference in reactivity between
these two polyols was observed (Tables 3 and 4).
[0226] Apparent Foam Cell Structure and Density
[0227] Free-rise foams based on Novomer polyols exhibited similar
white color to the reference foams prepared with Poly-G 85-29
polyol as sole polyol and reference foams prepared with 10% and 25%
graft polyol Speciflex NC-701. The apparent cell structure of foams
with Novomer polyols was uniform and similar to the reference
foams.
[0228] Density of the free-rise foams did not change significantly
with replacement of the reference polyol with 5%-25% Novomer
polyols (Tables 3 and 4).
TABLE-US-00003 TABLE 3A Formulation screening of PU foams based on
58-103-C Polyol Designation 1 2 3 4 5 Sample designation Eqv.
10%-58- 10%-58- 10%-58- 10%-58- F Weight REF-1 103-C-1 103-C-2
103-C-3 103-C-4 Polyol system Poly-G 85-29 3 2047.5 97 87.3 87.3
87.3 87.3 Novomer 58-103-C 471.43 0 9.7 9.7 9.7 9.7 Water 2 9 3.6
3.6 3.6 3.6 3.6 Lumulse POE 26 416.2 3 3 3 3 3 Tegostab B 4690
1335.7 1 1 1 1 1 Dabco 33LV 105 0.8 0.8 0.8 0.8 0.8 Diethanolamine
35.04 1 1 0.6 0.4 0.4 Niax A-1 233.7 0.1 0.1 0.1 0.1 0.15
Isocyanate System Mondur MRS-2 130.03 57.12 59.42 58.09 57.42 57.44
Isocyanate Index 90 90 90 90 90 % Novomer polyol 0% 10% 10% 10% 10%
on total polyols Reaction Profile of Free-rise Mix time, sec. 7 7 7
7 7 Cream time, sec. 10 .+-. 0.6 9 12 13 10 Gel time, sec. 49 .+-.
1.0 39 51 51 48 Rise time, sec. 83 .+-. 1.5 68 99 106 107
Post-curing time 30 min 30 min 30 min 30 min 30 min &
temperature* @ 80.degree. C. @ 80.degree. C. @ 80.degree. C. @
80.degree. C. @ 80.degree. C. Properties Free-rise density, pcf
2.26 -- -- -- -- Resilience, % 60.55 .+-. 0.73 -- -- -- -- Tensile
Strength, psi 14.31 .+-. 1.06 -- -- -- -- Elongation at Break, %
104.53 .+-. 7.92 -- -- -- -- Tear Strength, lbf/in 2.70 .+-. 0.05
-- -- -- -- CFD @ 25%, psi 0.20 .+-. 0.02 -- -- -- -- CFD @ 50%,
psi 0.34 .+-. 0.03 -- -- -- -- CFD @ 65%, psi 0.59 .+-. 0.05 -- --
-- -- Hysteresis 31.08 .+-. 1.16 -- -- -- -- Tensile Strength 13.26
.+-. 0.58 -- -- -- -- (Dry Heat Aged), psi Elongation at Break
128.05 .+-. 10.50 -- -- -- -- (Dry Heat Aged), % Dry Compression
Set, % 5.3 .+-. 0.68 -- -- -- -- Wet Compression Set, % 7.9 .+-.
0.73 -- -- -- -- SAG factor (65/25)** 2.95 -- -- -- -- SAG factor
(50/25)** 1.7 -- -- -- -- Comments No shrinkage, Shrinkage,
Shrinkage, Shrinkage, Shrinkage, open cells; closed cells; closed
cells; closed cells; closed cells; *Samples were placed in an oven,
for post-curing, after rise time. Samples were cut & crushed
after the first 10 minutes of curing. **SAG factor: CFD@65%/CFD25%
and CFD@50%/CFD25%
TABLE-US-00004 TABLE 3B Formulation screening of PU foams based on
Novomer 58-103-C Polyol Designation 1 2 3 4 5 6 Sample designation
Eqv. 5%-58- 10%-58- 15%-58- 20%-58- 25%-58- 25%-58- F Weight
103-C-1 103-C-5 103-C-1 103-C-1 103-C-1 103-C-2 Polyol system
Poly-G 85-29 3 2047.5 92.15 87.3 82.45 77.6 72.75 72.25 Novomer
58-103-C 471.43 4.85 9.7 14.55 19.4 24.25 24.25 Water 2 9 3.6 3.6
3.6 3.6 3.6 3.6 Lumulse POE 26 416.2 3 3 3 3 3 3 Tegostab B 4690
1335.7 1 1 1 1 1 1 Dabco 33LV 105 0.5 0.5 0.5 0.5 0.8 0.5
Diethanolamine 35.04 2 2 2 2 0.6 2 Niax A-1 233.7 0.1 0.1 0.1 0.1
0.1 0.10 Isocyanate System Mondur MRS-2 130.03 61.50 62.43 63.35
64.28 60.87 65.21 Isocyanate Index 90 90 90 90 90 90 % Novomer
polyol 5% 10% 15% 20% 25% 25% on total polyols Reaction Profile of
Free-rise Mix time, sec. 7 7 7 7 7 7 Cream time, sec. 11 13 .+-.
0.6 12 .+-. 0.6 12 .+-. 0.6 9 11 .+-. 0.6 Gel time, sec. 44 52 .+-.
1.2 52 .+-. 1.7 50 .+-. 0.6 45 49 .+-. 2.6 Rise time, sec. 87 87
.+-. 2.5 103 .+-. 8.7 98 .+-. 1.5 100 84 .+-. 1.7 Post-curing time
30 min 30 min 30 min 30 min 30 min 30 min & temperature* @
80.degree. C. @ 80.degree. C. @ 80.degree. C. @ 80.degree. C. @
80.degree. C. @ 80.degree. C. Properties Free-rise density, pcf
2.41 2.16 2.19 2.07 -- 2.13 Resilience, % 55.05 .+-. 1.47 42.80
.+-. 1.90 38.96 .+-. 1.50 36.0 .+-. 0.70 -- 31.8 .+-. 1.30 Tensile
Strength, psi 13.24 .+-. 0.77 15.68 .+-. 1.89 18.14 .+-. 1.85 18.93
.+-. 1.94 -- 18.99 .+-. 2.5 Elongation at Break, % 105.23 .+-. 7.70
113.32 .+-. 14.06 105.75 .+-. 7.91 130.54 .+-. 13.35 -- 99.68 .+-.
13.02 Tear Strength, lbf/in 3.29 .+-. 0.18 3.73 .+-. 0.29 3.82 .+-.
0.25 4.45 .+-. 0.36 -- 4.80 .+-. 0.20 CFD @ 25%, psi 0.27 .+-. 0.05
0.32 .+-. 0.04 0.38 .+-. 0.03 0.45 .+-. 0.04 -- 0.70 .+-. 0.05 CFD
@ 50%, psi 0.44 .+-. 0.08 0.53 .+-. 0.11 0.65 .+-. 0.07 0.74 .+-.
0.07 -- 1.13 .+-. 0.09 CFD @ 65%, psi 0.78 .+-. 0.15 0.94 .+-. 0.21
1.15 .+-. 0.17 1.28 .+-. 0.15 -- 1.99 .+-. 0.20 Hysteresis 39.21
.+-. 0.15 44.83 .+-. 2.94 51.41 .+-. 0.08 62.09 .+-. 2.31 -- 68.55
.+-. 3.08 Tensile Strength -- 15.03 .+-. 1.66 -- -- -- -- (Dry Heat
Aged), psi Elongation at Break -- 112.25 .+-. 12.55 -- -- -- --
(Dry Heat Aged), % Dry Compression Set, % -- 14.0 .+-. 3.14 -- --
-- -- Wet Compression Set, % -- 18.4 .+-. 0.93 -- -- -- -- SAG
factor (65/25) 2.89 2.94 3.03 2.84 -- 2.84 SAG factor (50/25) 1.63
1.66 1.71 1.64 -- 1.61 Comments No shrinkage, No shrinkage, No
shrinkage, No shrinkage, Shrinkage, No shrinkage, open cells; open
cells; open cells; open cells; closed cells; open cells; *Samples
were placed in an oven, for post-curing, after rise time. Samples
were cut & crushed after the first 10 minutes of curing. ** SAG
factor: CFD@65%/CFD25% and CFD@50%/CFD25%
TABLE-US-00005 TABLE 4 Formulation screening of PU foams based on
74-276 Polyol Designation 1 2 3 4 5 Sample designation Eqv. 5%-74-
10%-74- 15%-74- 20%-74- 25%-74- F Weight 276-1 276-1 276-1 276-1
276-1 Polyol system Poly-G 85-29 3 2047.5 92.15 87.3 82.45 77.6
72.75 Novomer 74-276 918.46 4.85 9.7 14.55 19.4 24.25 Water 2 9 3.6
3.6 3.6 3.6 3.6 Lumulse POE 26 416.2 3 3 3 3 3 Tegostab B 4690
1335.7 1 1 1 1 1 Dabco 33LV 105 0.5 0.5 0.5 0.5 0.5 Diethanolamine
35.04 2 2 2 2 2 Niax A-1 233.7 0.1 0.1 0.1 0.1 0.1 Isocyanate
System Mondur MRS-2 130.03 60.91 61.26 61.60 61.94 62.28 Isocyanate
Index 90 90 90 90 90 % Novomer polyol 5% 10% 15% 20% 25% on total
polyols Reaction Profile of Free-rise Mix time, sec. 7 7 7 7 7
Cream time, sec. 11 10 .+-. 1 10 11 11 Gel time, sec. 49 47 .+-.
1.0 44 45 46 Rise time, sec. 88 87 .+-. 1.3 83 90 92 Post-curing
time 30 min 30 min 30 min 30 min 30 min & temperature* @
80.degree. C. @ 80.degree. C. @ 80.degree. C. @ 80.degree. C. @
80.degree. C. Properties Free-rise density, pcf 2.27 2.38 2.24 2.28
2.35 Resilience, % 55.10 .+-. 1.40 49.12 .+-. 1.47 44.46 .+-. 1.27
38.53 .+-. 0.73 36.42 .+-. 1.47 Tensile Strength, psi 13.24 .+-.
0.77 15.34 .+-. 1.26 -- -- -- Elongation at Break, % 105.23 .+-.
7.70 100.19 .+-. 6.15 -- -- -- Tear Strength, lbf/in 3.29 .+-. 0.18
3.21 .+-. 0.17 -- -- -- CFD @ 25%, psi 0.28 .+-. 0.03 0.36 .+-.
0.05 0.35 .+-. 0.05 0.45 .+-. 0.07 0.53 .+-. 0.08 CFD @ 50%, psi
0.47 .+-. 0.05 0.59 .+-. 0.09 0.56 .+-. 0.07 0.75 .+-. 0.11 0.87
.+-. 0.13 CFD @ 65%, psi 0.86 .+-. 0.11 1.05 .+-. 0.18 0.96 .+-.
0.11 1.35 .+-. 0.18 1.57 .+-. 0.23 Hysteresis 35.10 .+-. 2.5 41.96
.+-. 1.87 46.15 .+-. 2.89 54.59 .+-. 1.06 56.45 .+-. 1.72 Tensile
Strength 12.27 .+-. 1.02 13.95 .+-. 0.81 -- -- -- (Dry Heat Aged),
psi Elongation at Break 93.45 .+-. 7.49 105.67 .+-. 5.20 -- -- --
(Dry Heat Aged), % Dry Compression Set, % 6.7 .+-. 1.71 8.2 .+-.
2.61 -- -- -- Wet Compression Set, % 12.7 .+-. 0.83 14.7 .+-. 2.94
-- -- -- SAG factor (65/25) 3.07 2.92 2.74 3.00 2.96 SAG factor
(50/25) 1.68 1.64 1.60 1.67 1.64 Comments No shrinkage, No
shrinkage, No shrinkage, No shrinkage, No shrinkage, open cells;
open cells; open cells; open cells; open cells; *Samples were
placed in an oven, for post-curing, after rise time. Samples were
cut & crushed after the first 10 minutes of curing. ** SAG
factor: CFD@65%/CFD25% and CFD@50%/CFD25%
TABLE-US-00006 TABLE 5 Formulation screening of PU foams based on
Speciflex NC-701 Polyol Designation 1 2 3 4 5 Sample designation
Eqv. 10%-NC- 25%-NC- F Weight 701-1 701-1 Polyol system Poly-G
85-29 3 2047.5 87.3 72.75 Speciflex NC-701 2244 9.7 24.25 Water 2 9
3.6 3.6 Lumulse POE 26 416.2 3 3 Tegostab B 4690 1335.7 1 1 Dabco
33LV 105 0.8 0.8 Diethanolamine 35.04 1 1 Niax A-1 233.7 0.1 0.1
Isocyanate System Mondur MRS-2 130.03 57.01 56.18 Isocyanate Index
90 90 % Novomer polyol 10% 25% on total polyols Reaction Profile of
Free-rise Mix time, sec. 7 7 Cream time, sec. 11 10 Gel time, sec.
42 33 Rise time, sec. 64 47 Post-curing time 30 min 30 min &
temperature* @ 80.degree. C. @ 80.degree. C. Properties Free-rise
density, pcf 2.26 2.29 Resilience, % 54.20 .+-. 1.47 51.24 .+-.
1.94 Tensile Strength, psi 13.65 .+-. 2.07 14.79 .+-. 0.98
Elongation at Break, % 109.16 .+-. 9.65 91.96 .+-. 11.29 Tear
Strength, lbf/in 3.10 .+-. 0.20 3.08 .+-. 0.75 CFD @ 25%, psi 0.30
.+-. 0.03 0.41 .+-. 0.05 CFD @ 50%, psi 0.51 .+-. 0.05 0.69 .+-.
0.06 CFD @ 65% psi 0.91 .+-. 0.11 1.22 .+-. 0.11 Hysteresis 33.86
.+-. 3.17 37.78 .+-. 3.16 Tensile Strength 12.65 .+-. 0.88 -- (Dry
Heat Aged), psi Elongation at Break 125.92 .+-. 7.77 -- (Dry Heat
Aged), % Dry Compression Set, % 7.3 .+-. 1.31 -- Wet Compression
Set, % 8.7 .+-. 1.64 -- SAG factor (65/25) 3.03 2.97 SAG factor
(50/25) 1.70 1.68 Comments No shrinkage, No shrinkage, open cells;
open cells; *Samples were placed in an oven, for post-curing, after
rise time. Samples were cut & crushed after the first 10
minutes of curing. ** SAG factor: CFD@65%/CFD25% and
CFD@50%/CFD25%
TABLE-US-00007 TABLE 6 Molded foams Designation 1 2 3 4 Sample
designation Eqv. 10%-58- 20%-58- F Weight REF-1 NC-701 103-C-5
103-C-1 Polyol system* Poly-G 85-29 3 2047.5 97 87.3 87.3 77.6
Novomer 58-103-C 471.43 0 -- 9.7 19.4 Speciflex NC-701 2244 9.7
Water 2 9 3.6 3.6 3.6 3.6 Lumulse POE 26 416.2 3 3 3 3 Tegostab B
4690 1335.7 1 1 1 1 Dabco 33LV 105 0.8 0.8 0.5 0.5 Diethanolamine
35.04 1 1 2 2 Niax A-1 233.7 0.1 0.1 0.1 0.1 Isocyanate System
Mondur MRS-2 130.03 57.12 57.01 62.43 64.28 Isocyanate Index 90 90
90 90 % Novomer polyol 0% 0% 10% 20% on total polyols Reaction
Profile 7 Mix time, sec. 7 7 7 7 De-molding time 4:30 min 4:30 min
4:30 min 4:30 min & temperature** @ 70.degree. C. @ 70.degree.
C. @ 70.degree. C. @ 70.degree. C. Properties Molded foam density,
pcf 3.30 3.31 3.43 3.14 Resilience, % 55.05 .+-. 1.4 52.93 .+-.
0.73 38.95 .+-. 1.5 36.0 .+-. 0.73 CFD @ 25%, psi 0.55 .+-. 0.03
0.57 .+-. 0.06 0.86 .+-. 0.03 1.01 .+-. 0.06 CFD @ 50%, psi 0.88
.+-. 0.04 0.87 .+-. 0.10 1.40 .+-. 0.04 1.59 .+-. 0.15 CFD @ 65%,
psi 1.58 .+-. 0.22 1.43 .+-. 0.20 2.45 .+-. 0.05 2.74 .+-. 0.32 SAG
factor (65/25) 2.87 2.51 2.85 2.71 SAG factor (50/25) 1.60 1.53
1.63 1.57 *The amount used for preparation of molded foams was
twice the amount shown in the table **Mold was heated at 70.degree.
C.; De-molding time was 270 sec.
[0229] The apparent cell structure of molded foams prepared with
10% and 20% 58-103C PPC polyol was uniform and similar to the
reference foams prepared with Poly-G 85-29 polyol as sole polyol
and reference foams prepared with 10% graft polyol Speciflex
NC-701.
[0230] Foam Physical Properties
[0231] Reference free-rise foams prepared with a graft polyol
(Speciflex NC-701) also exhibited somewhat lower resilience and
somewhat higher hysteresis in comparison to the reference foam
prepared with base polyol (Poly-G 85-29) as sole polyol (Tables 3A
and 5). In comparison to the foams based on graft polyols, foams
based on Novomer poloyols exhibited somewhat lower resilience and
somewhat higher hysteresis at the same load (Tables 3B, 4, and
5).
[0232] All foams prepared with Novomer polyols, included molded
foams, exhibited relatively high resilience and can be classified
as High Resilient (HR) PU foams.
[0233] In general, the tensile strength increased with introduction
of Novomer polyols. With introduction of Novomer polyol the
elongation did not change significantly (Tables 3 and 4). Tensile
strength and elongation of foams based on Novomer polyols was
similar to those based on graft polyol at the same load (Tables
3-5). These results indicate that the foam strength (toughness)
increases by introduction of the Novomer polyols.
[0234] The tear strength measured on foams prepared with Novomer
polyols was significantly higher in comparison to the reference
foam prepared with base polyol as sole polyol (Tables 3 and 4). The
tear strength of foams based on Novomer polyols were somewhat
higher in comparison to the reference foams prepared with graft
polyol (Tables 3-5). These results also indicate that the foam
strength (toughness) increases by introduction of the Novomer
polyols.
[0235] Free-rise foams based on Novomer polyols exhibited
significantly higher Compression Force Deflection (CFD) at 25%,
50%, and 65% deflections in comparison to the reference foam
prepared with base polyol as sole polyol (Tables 3 and 4; FIGS.
1-2) and slightly higher in comparison to the reference foams based
on graft polyol (Tables 3-5; FIG. 3). These results clearly
indicate that Novomer polyols improve the load bearing properties
of the flexible foams. More importantly, the SAG factor was not
affected by the introduction of Novomer polyols into foam
formulations (Tables 3-5; FIGS. 4 and 5). Similar effect of Novomer
polyol on CFD properties was observed in the case of molded foams
(Table 6).
[0236] Slight decrease in tensile strength was observed in all
foams that were tested for resistance to dry aging for 22 hours at
140.degree. C. However, no major difference in retention of
properties was observed between reference foams with and without
graft polyol and foams prepared with Novomer polyols (Tables
3-5).
[0237] Conclusions
[0238] Reactivity of Novomer polyols was comparable to the
reactivity of the reference polyol Poly-G 85-29 and graft polyol
Speciflex NC-701. However, in order to get open cell structure some
adjustments in catalysis and amount of diethanolamine (reactive
catalyst/cross-linker) was required.
[0239] Freer-rise foams prepared with 5%-25% Novomer polyols
exhibited uniform cell structure. Both the density and apparent
cell structure of these foams were comparable to the reference
foams prepared with and without graft polyol.
[0240] All foams prepared with 5%-25% Novomer polyols exhibited
relatively high resilience and can be classified as High Resilient
(HR) PU foams. All these foams exhibited comparable properties to
the reference foams which meets most of the properties specified by
Chrysler Material Standard: MS-DC-649 for "Cellular, Molded
Polyurethane High Resilient (HR) Type Seat Applications".
[0241] The tensile strength and tear strength properties of foams
prepared with Novomer polyols were better in comparison to the
reference foams. The retention of stress-strain properties with
heat aging was not affected by introduction of Novomer polyols.
[0242] Results of CFD measurements clearly indicate an increase in
load bearing properties of free-rise and molded foams based on
Novomer polyols without affecting the SAG (comfort) factor.
Example 2: Viscoelastic Foam Compositions
[0243] Presented below are the formulations of viscoelastic
polyurethane foams according to the principles of the present
invention. These materials were made using aliphatic polycarbonate
polyol additives as defined herein. Specifically, the aliphatic
polycarbonate polyols hereinafter also referred to as "Novomer
Polyols" used in the formulations below have the following
properties:
TABLE-US-00008 58-103-C 74-217 74-277 Acid Value, mg KOH/g 0.28
0.02 0.01 Hydroxyl Value, mg KOH/g 119 169.95 67.07 Mn (GPC) 1,270
810 2290 Mw (GPC) 1,370 920 2400 Polydispersity, Mw/Mn 1.07 1.13
1.05 Glass Transition Temp. -5.degree. C. -20.degree. C. -5.degree.
C. (DSC), Tg Viscosity, cPs 4,990 330 3700 @ 80.degree. C. @
75.degree. C.- @ 75.degree. C.
[0244] Polyol 58-103-C is a linear 1270 g/mol poly(propylene
carbonate) polyol initiated with dipolypropylene glycol (a mixture
of isomers) having a PDI of 1.06, greater than 99% --OH end groups
and greater than 99% carbonate linkages (exclusive of the ether
bond in the dipropylene glycol). This polyol conforms to the
formula:
##STR00013## [0245] where n is, on average in the composition,
approximately 5.6.
[0246] Polyol 74-217 is a linear 810 g/mol poly(propylene
carbonate) polyol initiated with dipolypropylene glycol (a mixture
of isomers) having a PDI of 1.13, greater than 99% --OH end groups
and greater than 99% carbonate linkages (exclusive of the ether
bond in the dipropylene glycol). This polyol conforms to the
formula:
##STR00014## [0247] where n is, on average in the composition,
approximately 3.3.
[0248] Polyol 74-277 is a linear 2400 g/mol poly(propylene
carbonate) polyol initiated with 600 g/mol polypropylene glycol
(mixture of isomers) having a PDI of 1.05, greater than 99% --OH
end groups and greater than 99% carbonate linkages (exclusive of
the ether bonds in the polypropylene glycol). This polyol conforms
to the formula:
##STR00015## [0249] where k is on average about 10, and n is on
average in the composition approximately 9.
[0250] The effect of PPC diols on load bearing (CFD) and other
properties of visco-elastic polyurethane foams were evaluated in
this study. Foams were also prepared using a mixture of Novomer PPC
polyols. Mondur MRS-2 with high content of 2,4'-MDI was used as an
isocyanate in preparation of foams. Properties of visco-elastic
foams prepared with NOVOMER polyols were compared to properties of
reference model formulation prepared with conventional polyols.
Raw Materials
[0251] A list of raw materials used in this evaluation is shown in
Table 1B. All materials were used as received including Novomer
polyols.
TABLE-US-00009 TABLE 1B Materials Designation Type Supplier POLYOLS
Novomer Polyol Novomer Poly(Propylene Carbonate) Novomer Batch
#58-103-C Hydroxyl Value = 119 mg KOH/g; Eq. wt. = 471.43 Acidity
Value = 0.28 mg KOH/g Novomer Polyol Hydroxyl Value = 169.95 mg
KOH/g; Novomer Batch #74-217 Eq. wt. = 330.1 Acidity Value = 0.02
mg KOH/g Novomer Polyol Hydroxyl Value = 67.07 mg KOH/g; Novomer
Batch #74-277 Eq. wt. = 836.4 Acidity Value = 0.01 mg KOH/g Poly G
30-240 Oxypropylated polyether triol Arch Hydroxyl Value = 238 mg
KOH/g; Eq. wt. = 235.7 Poly G-76-120 Ethylene oxide capped
polyether triol Arch Hydroxyl Value = 119.3 mg KOH/g; Eq. wt. =
467.5 Poly G-85-34 Ethylene oxide capped polyether triol Arch
Hydroxyl Value = 35 mg KOH/g; Eq. wt. = 1602.9 SURFACTANTS Tegostab
B 4690 Polyether/Silicone Oil Mix Evonik Eq. Wt. = 1335.7 CELL
OPENER Lumulse POE 26 Hydroxyl Value = 134.8 mg KOH/g Lambent Eq.
Wt = 416.2 CHAIN EXTENDER DEG Diethylene glycol Interstate Chem.
Com. CATALYSTS Dabco 33LV 33% Triethylene diamine in Air Products
dipropylene glycol Niax A1 bis(2-dimethylaminoethyl) ether
Momentive ISOCYANATES Mondur MRS-2 2,4' rich diphenylmethane Bayer
diisocyanate (F = 2.2; Eq. wt. = 129.9; % NCO = 32.35) FILLER
Calcium carbonate Calcium carbonate, Powder-Technical Spectrum
Preparation and Testing of Foams
[0252] Free rise water-blown foams were prepared with 0%/O, 10%,
and 20% Novomer 58-103-C, Novomer 74-217, and Novomer 74-277
polyols as replacements for petroleum based commercial polyols. VE
foams were also prepared using a mixture of the three Novomer
polyols up to 30% and 45% levels as replacements for the petroleum
based commercial polyols (Tables 2B-5B). Reference VE foams and VE
foams based on Novomer polyols were also prepared with CaCO.sub.3
as filler (Tables 2B-5B).
[0253] Most of the VE foams in this Example were prepared at an
Isocyanate Index of 70 with Mondur.TM. MRS-2, which is a 2,4'-MDI
rich isocyanate (Tables 2B-5B). Foams based on 30% and 45% mixture
of the three Novomer polyols were also prepared at an Isocyanate
Index of 80 (Table 5B).
[0254] Free-rise foams were prepared using a standard laboratory
hand-mixing procedure. Foaming profiles, including cream time, gel
time, and rise time were measured on all foams. After the rise
time, the foams were immediately placed in an air-circulating oven
preheated at 70.degree. C. for 60 minutes to complete the cure.
[0255] The full characterization was carried out on selected foams
after aging for a minim 7 days according to ASTM D 3574-08 as
follows: [0256] Foam Density (Test A), [0257] Resilience via Ball
Rebound (Test H), [0258] Tensile Strength at Break (Test E), [0259]
Elongation at Break (Test E), [0260] Tear Strength (Test F), [0261]
CFD, Compression Force Deflection (Test C), [0262] Hysteresis
(Procedure B--CFD Hysteresis Loss), [0263] Dry Constant Deflection
Compression Set (Test D), [0264] Wet Constant Deflection
Compression Set (Test D & Wet Heat Aging, Test L)
[0265] Recovery Time was measured on Instron Tester using in-house
protocol. The following measurement parameters were employed:
[0266] Sample dimensions: 2''.times.2''.times.1'' [0267] Indentor
Foot Area: 64 mm.sup.2 [0268] Speed: 500 mm/min [0269] Indentation:
80% [0270] Hold Time: 60 sec.
[0271] The recovery time was measured according to the following
protocol: Place the test specimen on the supporting plate. Bring
the indentor foot into contact with the specimen. Immediately
indent the specimen 80% of its initial thickness at a speed of 500
mm/min and hold for 60 seconds. After 60 seconds dwell time, return
the indentor to 0%/o deflection at 500 mm/min, starting the
stopwatch immediately upon initiating the upward movement of the
indentor. Stop the watch as soon as the imprint of the indentor
foot is not visible, and record the time. Repeat the process on 2
additional specimens and calculate the average time.
[0272] Glass transition temperature was measured via the following
methods: [0273] DSC (DSC Q10 from TA instrument) under nitrogen at
heating rate of 20.degree. C. per minute in a temperature rate
between -80.degree. and +200.degree. C. [0274] DMA (DMA 2980 from
TA Instrument) under nitrogen at heating rate of 3.degree. C. per
minute in a temperature rate between -80.degree. and +130.degree.
C.
Results
[0275] A model VE foam formulation was based on three different
commercial polyether triols: Poly-G 30-240, Poly-G 76-120, and
Poly-G 85-34 with equivalent weights of .about.236, .about.468, and
.about.1603, respectively (Tables 1B-5B). Ethoxylated glycerol
Lumulse POE 26 with equivalent weight of .about.416 was used as a
cell opening polyol (Tables 1B-5B). Diethylene glycol (DEG) was
used as a chain extender. Dabco 33LV and Niax A-1 were used as
catalysts. Dabco 33LV catalyst promotes gelling reaction (reaction
of isocyanate with polyol) and blowing reaction (reaction of
isocyanate with water). Niax A-1 is a blowing catalyst.
[0276] The reactivity of the PU systems was not affected
significantly after 10% and 20% drop-in replacement of any of
commercial polyols (Tables 2B-4B) including the cell opening polyol
(Table Table 2B) with Novomer polyls. The reactivity of the PU
system was not significantly affected after 30% and 45% drop-in
replacement of commercial polyols with a mixture of the three
Novomer polyols (Table 5B). No adjustment in catalysis was required
to obtain open cell foams with Novomer polyols (Tables 2B-5B).
[0277] VE foams based on Novomer polyols exhibited a white color
similar to the reference foams. The apparent cell structure of
foams with Novomer polyols was uniform and similar to the reference
foams.
Foam Physical Properties
[0278] Compression Force Deflection (CFD) at 25%, 50%, and 65%
deflection was increased by introduction of Novomer polyols (Tables
2B-5B and FIGS. 6, 10, 12, and 15). CFD values normalized for the
density clearly indicate that foams with Novomer polyol have higher
CFD (better load bearing properties) in comparison to the reference
foams (Tables 2B-5B and FIGS. 7, 10, 13, and 16). CFD graphs are
shown in FIGS. 6-19.
[0279] Hysteresis Loss, which is independent of foam density, also
increased with introduction of Novomer polyols (Tables 2B-5B and
FIGS. 8, 11, 14, and 17) which indicates that foams based on
Novomer polyols are more energy absorbing than the reference foams.
In general, Hysteresis Loss is a more reliable measure of energy
absorption than resilience measured via the Ball Rebound Method.
All foams prepared in this study exhibited very low resilience of
1% or less (Tables 2B-5B).
[0280] The tensile strength (FIGS. 6-20) and tear strength (FIGS.
20-23) of the VE foams was increased by introduction of Novomer
polyol 58-103-C as a replacement for Poly-G 76-120 polyols of
similar equivalent weight, both with and without calcium carbonate
filler (compare formulations 1 and 2 with formulations 4 and 5 in
Table 2B). The tensile and tear strengths measured are consistent
with the CFD properties of these foams.
[0281] The increase in tensile strength and tear strength
properties was especially high in foams prepared with a
proportional mixture of the three Novomer polyols at 30% and 45%
replacement of the three commercial base polyols (compare
formulations 1 and 2 with formulations 3 and 4 in Table 5B). As
expected, with an increase in isocyanate index from 70 to 80 the
tensile strength and tear strength increased even more in the foams
based on a mixture of Novomer polyols (compare formulations 3 and 4
with formulations 5 and 6 in Table 5B).
[0282] In most foams tested, the elongation at break was much
higher than the elongation (% strain) at maximum load. In order to
be consistent, the elongation at maximum load was reported as the
elongation. Without exception, all foams exhibited elongation
greater than 100% (Tables 2B-5B).
[0283] Recovery time after indentation to 80% of its initial
thickness was not significantly affected in foams prepared using
just one of Novomer polyols (Tables 2B-4B). However, foams prepared
with a proportional mixture of the three Novomer polyols at 30% and
45% levels as replacement for base commercial polyols exhibited
huge increase in the recovery time in comparison to the reference
foam (Table 5). This is consistent with the hysteresis values of
these foams (Tables 5B).
[0284] Dray and wet compression set was measured on selected number
of foams. In all foams containing up to 30% Novomer polyols based
on total polyols both dry and wet compression sets were relatively
low and comparable to the reference foam (Tables 2B-5B).
DMA and DSC Results
[0285] DMA and DSC graphs of selected foams are shown in FIGS.
18-23. Transitions in DMA and DSC graphs are summarized in table on
the next page.
[0286] Reference foam (REF-3, Formulation #1 in Tables 2-5)
exhibited Tg at -46.degree. C. which corresponds to first maximum
in loss modulus as measured via DMA (FIG. 18a; see Table 1C). Tan
delta peak was broad and exhibited low height with maximum at
35.degree. C. In general, the area under Tan Delta peak relates to
energy absorbing properties; larger area should relate to higher
energy absorbing properties. The foam that has low Tg and high area
under Tan delta curve is considered desirable for memory foams.
[0287] Foam based on 20% Novomer 74-217 polyol (Formulation #4 in
Table 3B) exhibited a Tg similar to the reference foam, as measured
by DMA (See Table 1C). The Tg measured via DSC was also similar to
the reference foam (Table 1C). Tan delta max measured on the foam
incorporating 20% Novomer 74-217 polyol was at slightly higher
temperature in comparison to the reference foam. However, the tan
delta peak was significantly higher and area under the peak was
significantly larger in comparison to the reference foam which
indicates that the energy absorbing capacity is higher. These data
correlate very well with hysteresis measurements. Hysteresis Loss
of Novomer foam was 62% and that of the reference foam 36%
(Formulations #1 and #4 in Table 3B).
TABLE-US-00010 TABLE IC Transitions Measured via DMA and DSC Foam
Formulation # DMA transitions designation (Table #) Loss Modulus,
.degree. C. Tan delta max., .degree. C. DSC transitions Reference
foam F #1 (T #2B-5B) -46.4 (Tg); 35.25 (broad and 3.28 (Tg) -1.96;
+26.1 low height) PPC-0.8-DPG-20% F #4 (T #3B) -43.9 (Tg); 39.35
(broad and 6.82 (Tg) 3.08; 29.6(weak) high) Novomer 103C-5 F #3 (T
#2B) 3.08 (Tg); 29.3 30.2 (broad and -2.48 (Tg); medium high) 112
(weak) PPC-2.3-PEOL-20% F #4 (T #4B) -33.49 (Tg); 0.88; ~40 (broad
and 6.19 (Tg); 29.28 high) 114.31 (weak); 159.8 (weak) ISO 80% F #5
(T #5B) -41.38 (Tg); 13.81 49.75 (broad and 13.36 (Tg); high)
108.74 (weak) ISO 80%-15 F #6 (T #5B) 28.00 (Tg) 55.74 (broad and
17.37 (Tg); high) 110.08 (weak)
[0288] Foam based on 18% Novomer 58-103-C polyol (Formulation #3 in
Table 2B-2) exhibited significantly higher Tg than reference foam,
as measured by DMA (FIG. 18a and 19; see also table above). This
shift in Tg measured via DMA can be ascribed to the fact that
polyether polyol with high equivalent weight of 1603 was replaced
with Novomer polyol of relatively low equivalent weight (471)
(Formulations #1 and #3 in Table 2B-2). However, Tg as measured via
DSC was detected at slightly lower temperature in the case of
Novomer foam in comparison to the reference foam (FIGS. 21 and 22;
see also table above).
[0289] Tan delta max of this Novomer foam was at 30.degree. C.,
close to the reference foam. The area under the tan delta peak was
higher in comparison to the reference foam which indicates that the
energy absorbing capacity is higher (FIGS. 18 and 19). These
results are also consistent with hysteresis measured on these two
foams (Formulations #1 and #3 in Table 2B).
[0290] Foam based on 20% Novomer 74-277 polyol (Formulation #4 in
Table 4B) exhibited relatively low Tg (-33.49.degree. C.) as
measured via DMA and Tan delta peak is at 40.degree. C., which is
broad and high. Both Tg and Tan delta max are slightly shifted to
higher temperatures as compared to reference foam (FIGS. 18 and 19,
Table 1C). Energy absorbing properties as measured by DMA correlate
very well with hysteresis results. This foam exhibited
significantly higher hysteresis in comparison to the reference foam
(Formulation #1 and #4 in Table 4).
[0291] Foam prepared by using 30% mixture of 3 different Novomer
polyols (Formulation #5 in Table 5B) exhibited low Tg close to the
reference foam as determined via DMA. Tan delta peak was broad and
high with maximum at 50.degree. C., indicating significantly higher
energy absorbing capacity in comparison to the reference foam
(FIGS. 18 and 20a; Table 1C). Hysteresis value for this foam was
high, (73%) while that of the reference foam was 36% (Formulations
#1 and #5 in Table 5B).
[0292] Foam prepared by using 45% mixture of 3 different Novomer
polyols (Formulation #6 in Table 5B) exhibited relatively high Tg
in comparison to the reference foam and other foams prepared with
Novomer polyols (FIGS. 18-20, Table 1C). Tan delta maximum was at
56.degree. C., which is significantly higher in comparison to other
foams. Tan delta peak was high indicating large energy absorbing
capacity, which is consistent with the hysteresis loss of 83%
(Formulation #6 in Table 5B).
[0293] Based on DMA measurements it can be concluded that Novomer
polyols impart energy improved absorbing properties to the foam
which is a desirable property viso-elastic foams.
TABLE-US-00011 TABLE 2B-1 Visco-elastic foams formulated with
Novomer 58-103-C polyol Designation 1 2 3 4 6 Sample designation
Eqv. Novomer Novomer Novomer Weight REF-3 CaCO3-2 103C 1* 103C-2*
103C-4 Total Novomer 0 0 10 10 10 polyols, % Polyol system Novomer
58-103-C 471.4 0 0 10 10 10 Poly G 30-240 235.7 21 21 17 21 21 Poly
G 76-120 467.5 21 21 17 21 21 Poly G 85-34 1602.9 18 18 16 18 8
Lumulse POE 26 416.2 40 40 40 30 40 CaCO3 0 26 0 0 0 DEG 53.1 2.25
2.25 2.25 2.25 2.25 Water 9 2.3 2.3 2.3 2.3 2.3 Tegostab B 4690
1335.7 1.5 1.5 1.5 1.5 1.5 Dabco 33LV 105 0.1 0.1 0.1 0.1 0.1 Niax
A-1 233.7 0.2 0.2 0.2 0.2 0.2 Isocyanate System Mondure MRS-2 129.9
49.45 49.45 48.94 49.19 50.81 Isocyanate Index 70 70 70 70 70
Reaction Profile of Free-rise Mix time, sec. 10 10 10 10 10 Cream
time, sec. 15.33 14 13 16 14 Gel time, sec. 63.33 52 45 66 56 Rise
time, sec. 137.33 136 98 152 83 Post-curing time 60 min 60 min 60
min 60 min 60 min & temperature* @70.degree. @70.degree.
@70.degree. @70.degree. @70.degree. Properties Free-rise density,
pcf 2.87 .+-. 0.10 3.37 .+-. 0.14 2.56 .+-. 0.17 3.11 .+-. 0.16
3.15 .+-. 0.11 Resilience, % 0.86 .+-. 0.23 0.76 .+-. 0.31 0.25
.+-. 0.00 0.66 .+-. 0.14 0.56 .+-. 0.11 CFD @ 25%, psi 0.06 .+-.
0.01 0.08 .+-. 0.01 0.06 .+-. 0.02 0.15 .+-. 0.03 0.11 .+-. 0.01
CFD @ 50%, psi 0.09 .+-. 0.01 0.12 .+-. 0.01 0.09 .+-. 0.02 0.19
.+-. 0.04 0.16 .+-. 0.02 CFD @ 65%, psi 0.14 .+-. 0.02 0.19 .+-.
0.02 0.15 .+-. 0.04 0.28 .+-. 0.07 0.25 .+-. 0.03 Hysteresis .sup.
36 .+-. 3.22 45.40 .+-. 1.98 53.86 .+-. 1.36 68.66 .+-. 3.41 39.32
.+-. 2.51 Tensile Strength, psi 11.33 .+-. 1.89 9.83 .+-. 0.52
10.89 .+-. 1.84 17.13 .+-. 3.97 5.57 .+-. 1.65 Elongation at
Maximum 192 .+-. 34 163 .+-. 17 169 .+-. 66 180 .+-. 14 108 .+-. 23
Load, % Tear Strength, lbf/in 2.04 .+-. 0.07 2.45 .+-. 0.25 2.05
.+-. 0.24 3.00 .+-. 0.47 1.94 .+-. 0.03 Recovery Time, sec 3.91
.+-. 1.08 -- -- -- Dry Compression Set 2.7 .+-. 0.42 -- -- -- -- @
70.degree. C., % Wet Compression Set 2.2 .+-. 1.16 -- -- -- -- @
50.degree. C., % Comments *After rise time, samples were placed in
an oven for post-curing.
TABLE-US-00012 TABLE 2B-2 Visco-elastic foams formulated with
Novomer 58-103-C polyol Designation 1 2 3 4 5 6 Sample designation
Eqv. Novomer Weight REF-3 CaCO3-2 58-103C FOAM #3 FOAM#4 FOAM #5
Total Novomer 0 0 18 10 10 20 polyols, % Polyol system Novomer
58-103-C 471.4 0 0 18 10 10 20 Poly G 30-240 235.7 21 21 21 21 21
21 Poly G 76-120 467.5 21 21 21 11 11 1 Poly G 85-34 1602.9 18 18 0
18 18 18 Lumulse POE 26 416.2 40 40 40 40 40 40 CaCO3 0 26 0 0 26 0
DEG 53.1 2.25 2.25 2.25 2.25 2.25 2.25 Water 9 2.3 2.3 2.3 2.3 2.3
2.3 Tegostab B 4690 1335.7 1.5 1.5 1.5 1.5 1.5 1.5 Dabco 33LV 105
0.1 0.1 0.1 0.1 0.1 0.1 Niax A-1 233.7 0.2 0.2 0.2 0.2 0.2 0.2
Isocyanate System Mondure MRS-2 129.9 49.45 49.45 51.90 49.43 49.43
49.41 Isocyanate Index 70 70 70 70 70 70 Reaction Profile of
Free-rise Mix time, sec. 10 10 10 10 10 10 Cream time, sec. 15.33
14 14 17 14 14 Gel time, sec. 63.33 52 58 63 48 56 Rise time, sec.
137.33 136 83 156 129 131 Post-curing time 60 min 60 min 60 min 60
min 60 min 60 min & temperature* @70.degree. @70.degree.
@70.degree. @70.degree. @70.degree. @70.degree. Properties
Free-rise density, pcf 2.87 .+-. 0.10 3.37 .+-. 0.14 3.18 .+-. 0.17
3.07 .+-. 0.04 3.53 .+-. 0.31 3.18 .+-. 0.11 Resilience, % 0.86
.+-. 0.23 0.76 .+-. 0.31 0.56 .+-. 0.11 2.54 .+-. 0.00 2.54 .+-.
0.00 0.51 .+-. 0.00 CFD @ 25%, psi 0.06 .+-. 0.01 0.08 .+-. 0.01
0.08 .+-. 0.02 0.08 .+-. 0.01 0.14 .+-. 0.03 0.14 .+-. 0.02 CFD @
50%, psi 0.09 .+-. 0.01 0.12 .+-. 0.01 0.12 .+-. 0.02 0.12 .+-.
0.01 0.20 .+-. 0.04 0.19 .+-. 0.02 CFD @ 65%, psi 0.14 .+-. 0.02
0.19 .+-. 0.02 0.19 .+-. 0.03 0.19 .+-. 0.03 0.33 .+-. 0.07 0.29
.+-. 0.03 Hysteresis .sup. 36 .+-. 3.22 45.40 .+-. 1.98 42.56 .+-.
1.14 59.10 .+-. 0.69 61.70 .+-. 1.08 67.42 .+-. 1.66 Tensile
Strength, psi 11.33 .+-. 1.89 9.83 .+-. 0.52 5.20 .+-. 0.63 13.83
.+-. 1.63 16.15 .+-. 1.62 21.37 .+-. 0.81 Elongation at Maximum 192
.+-. 34 163 .+-. 17 124 .+-. 22 187 .+-. 5 176 .+-. 10 213 .+-. 33
Load, % Tear Strength, lbf/in 2.04 .+-. 0.07 2.45 .+-. 0.25 1.62
.+-. 0.25 2.82 .+-. 0.39 3.14 .+-. 0.32 3.59 .+-. 0.28 Recovery
Time, sec 3.91 .+-. 1.08 -- 3.30 .+-. 0.95 -- -- -- Dry Compression
Set 2.7 .+-. 0.42 -- 2.9 .+-. 2.78 -- -- -- @ 70.degree. C., % Wet
Compression Set 2.2 .+-. 1.16 -- 0.8 .+-. 0.38 -- -- -- @
50.degree. C., % *After rise time, samples were placed in an oven
for post-curing.
TABLE-US-00013 TABLE 3B Visco-elastic foams formulated with Novomer
PPC-0.8-DPG polyol Designation 1 2 3 4 5 Sample designation Eqv.
PPC 74- PPC 74- Weight REF-3 CaCO3-2 217-10% 217-20% FOAM #1 Total
Novomer 0 0 10 20 10 polyols, % Polyol system Novomer PPC 74-217
330.1 0 0 10 20 10 Poly G 30-240 235.7 21 21 16 11 16 Poly G 76-120
467.5 21 21 16 11 16 Poly G 85-34 1602.9 18 18 18 18 18 Lumulse POE
26 416.2 40 40 40 40 40 CaCO3 0 26 0 0 26 DEG 53.1 2.25 2.25 2.25
2.25 2.25 Water 9 2.3 2.3 2.3 2.3 2.3 Tegostab B 4690 1335.7 1.5
1.5 1.5 1.5 1.5 Dabco 33LV 105 0.1 0.1 0.1 0.1 0.1 Niax A-1 233.7
0.2 0.2 0.2 0.2 0.2 Isocyanate System Mondure MRS-2 129.9 49.45
49.45 49.30 49.15 49.30 Isocyanate Index 70 70 70 70 70 Reaction
Profile of Free-rise Mix time, sec. 10 10 10 10 10 Cream time, sec.
15.33 14 16 16 14 Gel time, sec. 63.33 52 48 48 43 Rise time, sec.
137.33 136 168 147 128 Post curing time 60 min 60 min 60 min 60 min
60 min & temperature* @70.degree. @70.degree. @70.degree.
@70.degree. @70.degree. Properties Free-rise density pcf 2.87 .+-.
0.10 3.37 .+-. 0.14 3.29 .+-. 0.11 3.22 .+-. 0.18 3.76 .+-. 0.22
Resilience, % 0.86 .+-. 0.23 0.76 .+-. 0.31 0.50 .+-. 0.00 0.13
.+-. 0.03 1.27 .+-. 0.00 CFD @ 25%, psi 0.06 .+-. 0.01 0.08 .+-.
0.01 0.10 .+-. 0.02 0.11 .+-. 0.03 0.09 .+-. 0.01 CFD @ 50%, psi
0.09 .+-. 0.01 0.12 .+-. 0.01 0.14 .+-. 0.03 0.15 .+-. 0.04 0.14
.+-. 0.02 CFD @ 65%, psi 0.14 .+-. 0.02 0.19 .+-. 0.02 0.22 .+-.
0.05 0.24 .+-. 0.08 0.21 .+-. 0.04 Hysteresis .sup. 36 .+-. 3.22
45.40 .+-. 1.98 43.62 .+-. 1.51 61.79 .+-. 1.81 57.21 .+-. 1.96
Tensile Strength, psi 11.33 .+-. 1.89 9.83 .+-. 0.52 11.55 .+-.
1.60 10.91 .+-. 0.37 9.59 .+-. 0.83 Elongation at Maximum 192 .+-.
34 163 .+-. 17 202 .+-. 16 213 .+-. 11 153 .+-. 15 Load, % Tear
Strength, lbf/in 2.04 .+-. 0.07 2.45 .+-. 0.25 1.90 .+-. 0.15 2.16
.+-. 0.16 2.39 .+-. 0.30 Recovery Time, sec 3.91 .+-. 1.08 -- --
10.48 .+-. 0.42 -- Dry Compression Set 2.7 .+-. 0.42 -- -- 3.3 .+-.
1.88 -- @ 70.degree. C., % Wet Compression Set 2.2 .+-. 1.16 -- --
1.5 .+-. 0.99 -- @ 50.degree. C., % *After rise time, samples were
placed in an oven for post-curing.
TABLE-US-00014 TABLE 4B Visco-elastic foams formulated with Novomer
74-277 polyol Designation 1 2 3 4 5 Sample designation Eqv. 74- 74-
Weight REF-3 CaCO3-2 277-10% 277 -20% FOAM #2 Total Novomer 0 0 10
20 10 polyols, % Polyol system Novomer 74-277 836.4 0 0 10 20 10
Poly G 30-240 235.7 21 21 21 21 21 Poly G 76-120 467.5 21 21 16 11
16 Poly G 85-34 1602.9 18 18 13 8 13 Lumulse POE 26 416.2 40 40 40
40 40 CaCO3 0 26 0 0 26 DEG 53.1 2.25 2.25 2.25 2.25 2.25 Water 9
2.3 2.3 2.3 2.3 2.3 Tegostab B 4690 1335.7 1.5 1.5 1.5 1.5 1.5
Dabco 33LV 105 0.1 0.1 0.1 0.1 0.1 Niax A-1 233.7 0.2 0.2 0.2 0.2
0.2 Isocyanate System Mondure MRS-2 129.9 49.45 49.45 49.28 49.11
49.28 Isocyanate Index 70 70 70 70 70 Reaction Profile of Free-rise
Mix time, sec. 10 10 10 10 10 Cream time, sec. 15.33 14 14 11 13
Gel time, sec. 63.33 52 63 47 46 Rise time, sec. 137.33 136 132 129
115 Post-curing time 60 min 60 min 60 min 60 min 60 min &
temperature* @70.degree. @70.degree. @70.degree. @70.degree.
@70.degree. Properties Free rise density, pcf 2.87 .+-. 0.10 3.37
.+-. 0.14 3.30 .+-. 0.17 3.09 .+-. 0.07 3.60 .+-. 0.16 Resilience,
% 0.86 .+-. 0.23 0.76 .+-. 0.31 0.50 .+-. 0.00 0.23 .+-. 0.03 3.05
.+-. 0.70 CFD @ 25%, psi 0.06 .+-. 0.01 0.08 .+-. 0.01 0.15 .+-.
0.02 0.15 .+-. 0.01 0.14 .+-. 0.02 CFD @ 50%, psi 0.09 .+-. 0.01
0.12 .+-. 0.01 0.20 .+-. 0.03 0.20 .+-. 0.01 0.20 .+-. 0.03 CFD @
65%, psi 0.14 .+-. 0.02 0.19 .+-. 0.02 0.28 .+-. 0.05 0.30 .+-.
0.02 0.31 .+-. 0.05 Hysteresis .sup. 36 .+-. 3.22 45.40 .+-. 1.98
62.25 .+-. 3.67 60.96 .+-. 2.45 55.22 .+-. 1.41 Tensile Strength,
psi 11.33 .+-. 1.89 9.83 .+-. 0.52 13.05 .+-. 1.36 7.79 .+-. 1.16
16.49 .+-. 2.24 Elongation at Maximum 192 .+-. 34 163 .+-. 17 192
.+-. 14 196 .+-. 36 184 .+-. 4 Load, % Tear Strength, lbf/in 2.04
.+-. 0.07 2.45 .+-. 0.25 2.25 .+-. 0.16 2.47 .+-. 0.22 2.85 .+-.
0.17 Recovery Time, sec 3.91 .+-. 1.08 -- -- 15.74 .+-. 0.61 -- Dry
Compression Set 2.7 .+-. 0.42 -- -- 3.8 .+-. 1.09 -- @ 70.degree.
C., % Wet Compression Set 2.2 .+-. 1.16 -- -- -- -- @ 50.degree.
C., % *After rise time, samples were placed in an oven for
post-curing.
TABLE-US-00015 TABLE 5B Visco-elastic foams formulated with a
mixture of three different Novomer polyols Designation 1 2 3 4 5 6
Sample designation Eqv. ISO ISO- ISO ISO Weight REF-3 CaCO3-2
70%-10 70%-15 80% 80%-15 Total Novomer 0 0 30 45 30 45 polyols, %
Polyol system Novomer 58-103-C 471.4 0 0 10 15 10 15 Novomer 74-217
330.1 0 0 10 15 10 15 Novomer 74-277 836.4 0 0 10 15 10 15 Poly G
30-240 235.7 21 21 11 6 11 6 Poly G 76-120 467.5 21 21 11 6 11 6
Poly G 85-34 1602.9 18 18 8 3 8 3 Lumulse POE 26 416.2 40 40 40 40
40 40 CaCO3 0 26 0 0 0 0 DEG 53.1 2.25 2.25 2.25 2.25 2.25 2.25
Water 9 2.3 2.3 2.3 2.3 2.3 2.3 Tegostab B 4690 1335.7 1.5 1.5 1.5
1.5 1.5 1.5 Dabco 33LV 105 0.1 0.1 0.1 0.1 0.1 0.1 Niax A-1 233.7
0.2 0.2 0.2 0.2 0.2 0.2 Isocyanate System Mondure MRS-2 129.9 49.45
49.45 48.85 48.55 55.83 55.48 Isocyanate Index 70 70 70 70 80 80
Reaction Profile of Free-rise Mix time, sec. 10 10 10 10 10 10
Cream time, sec. 15.33 14 14 14 15 15.5 Gel time, sec. 63.33 52 49
45 48 47 Rise time, sec. 137.33 136 137 131 137 124 Post-curing
time 60 min 60 min 60 min 60 min 60 min 60 min & temperature*
@70.degree. @70.degree. @70.degree. @70.degree. @70.degree.
@70.degree. Properties Free-rise density, pcf 2.87 .+-. 0.10 3.37
.+-. 0.14 3.28 .+-. 0.19 3.31 .+-. 0.14 3.15 .+-. 0.13 3.02 .+-.
0.14 Resilience, % 0.86 .+-. 0.23 0.76 .+-. 0.31 0.86 .+-. 0.14
0.66 .+-. 0.14 1.47 .+-. 0.11 -- CFD @ 25%, psi 0.06 .+-. 0.01 0.08
.+-. 0.01 0.13 .+-. 0.02 0.23 .+-. 0.03 0.36 .+-. 0.03 0.49 .+-.
0.07 CFD @ 50%, psi 0.09 .+-. 0.01 0.12 .+-. 0.01 0.17 .+-. 0.02
0.29 .+-. 0.04 0.49 .+-. 0.05 0.62 .+-. 0.09 CFD @ 65%, psi 0.14
.+-. 0.02 0.19 .+-. 0.02 0.24 .+-. 0.01 0.41 .+-. 0.07 0.75 .+-.
0.10 0.79 .+-. 0.13 Hysteresis .sup. 36 .+-. 3.22 45.40 .+-. 1.98
77.40 .+-. 3.37 89.87 .+-. 0.45 72.62 .+-. 0.97 83.23 .+-. 1.64
Tensile Strength, psi 11.33 .+-. 1.89 9.83 .+-. 0.52 14.70 .+-.
5.31 21.67 .+-. 13.00 28.77 .+-. 5.78 29.32 .+-. 3.54 Elongation at
Maximum 192 .+-. 34 163 .+-. 17 201 .+-. 20 186 .+-. 49 192 .+-. 15
156 .+-. 14 Load, % Tear Strength, lbf/in 2.04 .+-. 0.07 2.45 .+-.
0.25 2.49 .+-. 0.17 3.34 .+-. 0.22 5.96 .+-. 0.64 6.44 .+-. 0.50
Recovery Time, sec 3.91 .+-. 1.08 -- 89 .+-. 13.45 .sup. 524 .+-.
109.5 .sup. 39 .+-. 7.55 177.7 .+-. 9.29 Dry Compression Set 2.7
.+-. 0.42 -- 6.0 .+-. 3.70 25.2 .+-. 9.13 2.4 .+-. 1.82 -- @
70.degree. C., % Wet Compression Set 2.2 .+-. 1.16 -- 3.6 .+-. 2.12
8.0 .+-. 3.51 3.2 .+-. 2.02 -- @ 50.degree. C., %
Conclusions
[0294] Reactivity of Novomer polyols in VE formulations was
comparable to the reactivity of the reference polyols used in this
study. The reactivity of the PU system was not affected
significantly after 10% and 20% drop-in replacement of any of
commercial polyols used in this study including the cell opening
polyol. The reactivity of the PU system was not significantly
affected after 30% and 45% drop-in replacement of commercial
polyols with a mixture of the three Novomer polyols. No adjustment
in catalysis was required to obtain open cell foams with Novomer
polyols.
[0295] VE foams based on Novomer polyols exhibited similar white
color to the reference foams. The apparent cell structure of foams
with Novomer polyols was uniform and similar to the reference
foams.
[0296] Compression Force Deflection (CFD) at 25%, 50%/c, and 65%
deflection of VE foams was increased by introduction of Novomer
polyols. CFD values normalized for the density clearly indicate
that foams with Novomer polyol have higher CFD (better load bearing
properties) in comparison to the reference foams.
[0297] Hysteresis Loss, which is independent of foam density, also
increased with introduction of Novomer polyols which indicates that
foams based on Novomer polyols are more energy absorbing than
reference VE foams. All foams prepared in this study exhibited very
low resilience around 1% or less.
[0298] The tensile and tear strength of VE foams increased by
introduction of Novomer 58-103-C polyol as replacement for Poly-G
76-120 polyols of similar equivalent weight, with and without
calcium carbonate as filler. An increase in tensile strength and
tear strength properties is especially high in foams prepared with
a proportional mixture of the three Novomer polyols at 30% and 45%
replacement of the three commercial polyols.
[0299] An increase in isocyanate index from 70 to 80 the tensile
strength and tear strength increased in the VE foams based on a
mixture of Novomer polyols.
[0300] Elongation at break was much higher than the elongation (%
strain) at maximum load. In order to be consistent, the elongation
at maximum load was reported as the elongation. Without exception,
all VE foams exhibited elongation higher than 100%.
[0301] VE foams prepared with a proportional mixture of the three
Novomer polyols at 30% and 45% levels as replacement for base
commercial polyols exhibited huge increase in the recovery time in
comparison to the reference foam. This is consistent with the
hysteresis values of these foams.
[0302] Dray and wet compression set was measured on selected number
of VE foams. In all foams containing up to 30% Novomer polyols
based on total polyols both dry and wet compression sets were
relatively low and comparable to the reference foam.
[0303] Based on DMA measurements it can be concluded that Novomer
polyols impart improved energy absorbing properties to the VE foam
formulations which are consistent with the hysteresis loss results.
Higher energy absorption is a desirable characteristic in
visco-elastic foams.
Example 3: TDI-Based Seating Foams
[0304] Presented below are the formulations and properties of high
strength TDI-based polyurethane foams prepared according to the
principles of the present invention. These materials were made to
evaluate their suitability for seating foam applications. The TDI
foams were made using aliphatic polycarbonate polyol additives as
defined herein. Specifically, the aliphatic polycarbonate polyols
hereinafter also referred to as "Novomer Polyols" used in the
formulations below have the following properties:
TABLE-US-00016 Polyol Batch No. 58-103-C 74-276 80-148 80-163 Acid
Value, mg KOH/g 0.28 0.51 2.68 2.09 Hydroxyl Value, mg KOH/g 119
61.1 111.7 64.9 Mn (GPC) 1,270 2,213 1337 2205 Mw (GPC) 1,370 2,443
1453 2345 Polydispersity, Mw/Mn 1.07 1.06 1.09 1.06 Glass
Transition Temp. -5.degree. C. -5.5.degree. C. 6.0.degree. C.
-9.9.degree. C. (DSC), Tg
[0305] The structures of polyols 58-103-C and 74-276 are shown
above in previous examples.
[0306] Polyol 80-163 is a linear 2250 g/mol poly(propylene
carbonate) polyol initiated with 600 g/mol polypropylene glycol
(mixture of isomers) having a PDI of 1.05, greater than 99% --OH
end groups and greater than 99% carbonate linkages (exclusive of
the ether bonds in the polypropylene glycol). This polyol conforms
to the formula:
##STR00016## [0307] where k is on average about 9, and n is on
average in the composition approximately 7.
[0308] Polyol 80-148 is a linear poly(propylene carbonate) polyol
initiated with propylene glycol and having an Mn of 1340 g/mol, a
PDI of 1.09, greater than 99% --OH end groups and greater than 99%
carbonate linkages. This polyol conforms to the formula:
##STR00017## [0309] where n is, on average in the composition,
approximately 13.
Raw Materials
[0310] A list of raw materials used in this evaluation is shown in
Tables Ex3-1a and Ex3-1b.
[0311] All materials were used as received from suppliers including
Novomer polyols.
TABLE-US-00017 TABLE Ex3-1a Materials Designation Type Supplier
POLYOLS Poly-G 85-29 Ethylene oxide caped polyether Arch polyol
(triol) Chemicals Hydroxyl Value = 27.4 mg KOH/g; Eq. wt. =
2047.445 Viscosity @ 25.degree. C. = 1150 cPs Voranol- A
catalytically Active, DOW Voractiv 6340 High-functionality EO Gaped
Polyether Polyol; OH #32 mg KOH/g; Eq. wt. = 1753.13 Water content
= 0.031% Speciflex NC-701 Grafted polyether polyol containing DOW
copolymerized styrene and acrylonitrile Hydroxyl Value = 23.0 mg
KOH/g; Eq. wt. = 2439.13 Viscosity @ 25.degree. C. = 5070 mPa s
Novomer Novomer Poly(Propylene Carbonate) NOVOMER PPC-1.2-DPG
Hydroxyl Value = 119 mg KOH/g; Batch 58-103-C Eq. wt. = 471.43
Acidity Value = 0.28 mg KOH/g Viscosity @ 25.degree. C. = 1.25
.times. 10.sup.6 cPs Viscosity @ 80.degree. C. = 4990 cPs Novomer
Novomer Poly(Propylene Carbonate) NOVOMER PPC-1kd-PG Hydroxyl Value
= 111.72 mg KOH/g; Batch 80-148 Eq. wt. = 502.15 Acidity Value =
2.68 mg KOH/g Novomer Novomer Poly(Propylene Carbonate) NOVOMER
PPC-2kd-PEOL Hydroxyl Value = 64.94 mg KOH/g, Batch 80-163 Eq. wt.
= 863.87 Acidity Value = 2.09 mg KOH/g Novomer Novomer
Poly(Propylene Carbonate) NOVOMER PPC-2.3-PEOL Hydroxyl Value =
61.1 mg KOH/g; Batch 74-276 Eq. wt. = 918.47
TABLE-US-00018 TABLE Ex3-1b Materials Designation Type Supplier
SURFACTANTS Tegostab B 4690 Polyether/Silicone Oil Mix Evonik Eq.
Wt. = 1335.7 CELL OPENER Lumulse POE 26 Hydroxyl Value = 134.8
Lambent mg KOH/g Eq. Wt. = 416.2 CHAIN EXTENDERS Diethanolamine Eq.
Wt. = 35.04 Aldrich CATALYSTS Dabco 33LV 33% Triethylenediamine Air
Products in dipropylene glycol Niax A1 bis(2-dimethylaminoethyl)
Momentive ether ISOCYANATES Lupranate .RTM. T80 Type 1 Toluene
Disocyanate BASF Eq. wt. = 87.54
Solubility/Compatibility of Novomer Polyols with Commercial
Polyether Polyols
[0312] In foaming experiments, a formulation targeting high
resilient flexible foams was used as reference. This formulation is
based on a mixture of Poly-G 85-29 ethylene oxide tipped polyether
triol (polyol) and Voranol-Voractiv 6340 which is a catalytically
active, high functional EO caped polyether polyol. Speciflex NC-701
was used as grafted polyether polyol. Lumulse POE 26 (ethoxylated
glycerol) was used as a reactive cell opener. Diethanol amine was
used as a co-catalyst and cross-linker.
Preparation and Testing of Foams
[0313] Reference free rise water-blown foams were prepared with 0%,
10%, and 20% Speciflex NC-701 graft polyol at 90 Isoctanate Index
(Tables Ex3-2 to Ex3-5). Reference molded foams were prepared with
0%, 10%, 15%, 20%, and 25% Speciflex NC-701 graft polyol (Tables
Ex3-6 to Ex3-10).
[0314] Both free-rise and molded foams were prepared with 10% and
20% Novomer PPC-2kd-PEOL polyol (Table Ex3-3 and Ex3-8). At 20%
80-163 polyol-containing molded foams were prepared targeting 2.5
and 3.5 pcf foam density (Table 8A).
[0315] Due to the limited compatibility with commercial polyols,
free-rise foams were prepared with 10% and molded foams with 10%
and 15% of polyol 80-148 (Table Ex3-5 and Ex3-10). Molded foams
containing 15% 80-148 polyol were prepared targeting 2.5 and 3.5
pcf foam density (Table Ex3-10).
[0316] Free-rise foams were prepared with 10%, 12.5% and 26.9%
polyol 74-276 (Table Ex3-2) and 10%, 12.5% and 16.7% 58-103C polyol
(Table Ex3-4). Molded foams were prepared with 10% of each of these
two polyols (Tables Ex3-7 and Ex3-9) and 20% polyol 74-276 (Table
Ex3-7).
[0317] In some cases, free-rise and molded foams were prepared with
a mixture of Speciflex NC-701 graft polyether polyol and Novomer
polyols (Tables Ex3-2 to Ex3-4, Ex3-7, Ex3-8B, and Ex3-9).
[0318] Free-rise foams were prepared using a standard laboratory
hand-mixing procedure. Foaming profiles, including cream time, gel
time, and rise time were measured on all foams. After the rise
time, the foams were immediately placed in an air-circulating oven
preheated at 80.degree. C. for 30 minutes to complete the cure.
[0319] Molded foams were prepared using an aluminum mold with
12.times.12.times.2 inch dimensions preheated at 70.degree. C.
Demolding time was 4.5 minutes.
[0320] All foams were aged under room conditions for minimum one
week before testing. Full evaluation was carried out on molded
foams. The following properties were measured according to ASTM D
3574-08: [0321] Foam Density (Test A) [0322] Resilience via Ball
Rebound (Test H) [0323] Tensile Strength at Break (Test E) [0324]
Elongation at Break (Test E) [0325] Tear Strength (Test F) [0326]
CFD, Compression Force Deflection (Test C) [0327] Hysteresis
(Procedure B--CFD Hysteresis Loss) [0328] Dry Constant Deflection
Compression Set (Test D) [0329] Wet Constant Deflection Compression
Set (Test D & Wet Heat Aging, Test L) [0330] Tensile strength
and Elongation after Dry Heat Aging for 22 hours at 140.degree. C.
(Modified Heat Aging Test K)
[0331] Flammability was measured as Horizontal Burning Rate
according to the in-house method, which was modified from ASTM D
5132-04.
IV. Results
[0332] Polyol Compatibility
[0333] After 24 hours, Novomer PPC-2kd-PEOL polyol was compatible
up-to 25% levels with a 50/50 mixture of Poly-G 85-29 polyol and
Voranol 6340 polyol.
[0334] Novomer polyol 80-148 was compatible with a mixture of the
two commercial polyols up to 15% levels immediately after blending.
After 24 hours, the blend separated into a two phase system.
[0335] Polyol Reactivity
[0336] Introduction of the four different Novomer polyols into
reference foam formulation as drop-in replacement for Poly-G 85-29
and Voranol Voractiv 6340 did not significantly affect the reaction
profile (foaming profile) measured as cream time, gel time, and
rise time (Tables Ex3-2 to Ex3-5). No adjustment in catalyst was
need.
[0337] Apparent Foam Cell Structure and Density
[0338] Free-rise foams based on Novomer polyols exhibited similar
white color to the reference foams prepared with or without graft
polyol Speciflex NC-701. The apparent cell structure of foams with
Novomer polyols was uniform and similar to the reference foams.
[0339] Density of the free-rise foams did not change significantly
with a drop-in replacement of Poly-G 85-29 and Voranol Voractiv
6340 polyols with Novomer polyols (Tables Ex3-2 to Ex3-5).
[0340] The apparent cell structure of molded foams prepared with
Novomer polyols was uniform and similar to the reference foams
prepared with a mixture of Poly-G 85-29 and Voranol Voractiv 6340
polyols and reference foams prepared with graft polyol Speciflex
NC-701.
[0341] Foam Physical Properties
[0342] In this study, free-rise foams were prepared mostly to
evaluate reactivity of epoxide-CO.sub.2 based polyols and their
effect on foaming profile. Free-rise TDI foams exhibited
significantly higher resilience in comparison to the MDI-based HR
foams prepared at the same levels of Novomer polyols (Example 1).
MDI-Based foams prepared with 10% and 25% Novomer polyol 74-276
exhibited resilience of 49% and 36%, respectively. TDI foams based
on 10% and 26.9% of the same polyol exhibited resilience of 53 and
42%. TDI foams prepared with 10% and 16.7% Novomer polyol 58-103
exhibited resilience of 55% and 45%, respectively, and MDI foams
prepared with 10% and 15% of the same polyol exhibited resilience
of 43% and 39%.
[0343] Reference free-rise foams prepared with a graft polyol
(Speciflex NC-701) also exhibited lower resilience in comparison to
the reference foam prepared with base polyether polyols.
[0344] The same effect of the graft polyol and Novomer polyols on
the resilience was observed in the molded foams (Tables Ex3-6 to
Ex3-10). In all cases, the resilience of the molded foams somewhat
decreased and hysteresis somewhat increased with introduction of
the graft polyol and Novomer polyols (Tables Ex3-6 to Ex3-10).
However, the resilience was significantly higher and hysteresis
significantly lower, regardless of the type of Novomer polyol
(Tables Ex3-6 to Ex3-10), in comparison to the MDI-based foams at
the same levels.
[0345] All molded TDI foams based on Novomer polyols exhibited
hysteresis lower than 35% (Tables 7-10, FIGS. 24 and 25), which is
a maximum specified by Chrysler Material standard for Type IV foams
with a minimum density requirement of 2 pcf (32 kg/m.sup.3) (FIG.
33), with one exception; the foam with 20% polyol 74-276 exhibited
hysteresis of 35.3% (Table Ex3-7). The density of all molded foams
was around 2.4 pcf (38 kg/m.sup.3).
[0346] Based on hysteresis results, all foams prepared with Novomer
polyols can be classified as High Resilient (HR) PU foams.
[0347] In general, the tensile strength increased with introduction
of Novomer polyols. With introduction of Novomer polyol the
elongation did not change significantly (Tables Ex3-7 to Ex3-10).
These results indicate that the foam strength (toughness) increases
by introduction of the Novomer polyols.
[0348] The tear strength measured on foams prepared with Novomer
polyols was significantly higher in comparison to the reference
foam prepared with the base polyether polyols Poly-G 85-29 and
Voranol Voractiv 6340 (Tables Ex3-7 to Ex3-9). The tear strengths
of foams based on polyol 75-276, 80-163, and 58-103-C polyols were
similar in comparison to the reference foams prepared with the
graft polyol (Tables Ex3-7 to Ex3-9). These results also indicate
that the foam strength (toughness) increases by introduction of the
Novomer polyols.
[0349] All molded foams based on Novomer polyols exhibited
significantly higher Compression Force Deflection (CFD) at 25%,
50%, and 65% deflections in comparison to the reference foam
prepared with the base polyols as sole polyols and similar or
slightly higher CFD in comparison to the reference foams based on
graft polyol (Tables Ex3-7 to Ex3-10, FIGS. 26-31). These results
clearly indicate that Novomer polyols improve the load bearing
properties of the flexible foams. More importantly, the SAG factor
was not affected significantly by the introduction of Novomer
polyols into foam formulations (Tables Ex3-7 to Ex3-10, FIG.
32).
[0350] The dry and wet compression set of molded foams based on
Novomer polyols was somewhat higher in comparison to the reference
foams (Tables Ex3-7 to Ex3-10). Molded foams prepared with the
graft polyol also exhibited slightly higher compression set values
in comparison to the reference foams prepared with the based
polyether polyol (Table Ex3-6). However, all molded foams prepared
with Novomer polyols meet the wet compression set requirements of
25% maximum defined by the Chrysler Material Standard for Type IV
foams (FIG. 33).
[0351] Practically all molded foams based on Novomer polyols met
the hysteresis loss, tear resistance, and wet compression
requirements of the Chrysler Material Standard for Type IV
foams.
[0352] The flammability of molded foams was not affected by
addition of Novomer polyols. The burning rate of all molded foams
based on Novomer polyols was around 100 mm/min which is in the
range of reference foams prepared with and without the graft polyol
(Tables Ex3-6, Ex3-7, Ex3-8A, Ex3-9, and Ex3-10. If needed, the
flammability of the foams can easily be adjusted by addition of
small amount of flame retardants.
[0353] Retention of tensile strength properties was excellent in
all measured foams after dry aging for 22 hours at 140.degree. C.
(Tables Ex3-6, Ex3-7, Ex3-8A, Ex3-9, and Ex3-10). In some cases,
the stress-strain properties improved with dry heat aging which was
not observed in MDI foams (Example 1). This might be ascribed to
the annealing effect under elevated temperature of TDI-based
polymer network.
Properties of Foams Prepared with NOVOMER Polyols Targeting Density
of 3.5 Pcf
[0354] The density of the molded foams described above was around
2.4 pcf (.about.38 kg/m.sup.3) which is in a range of Type IV HR
foams for seat applications according to Chrysler Material Standard
MS-DC-649 (FIG. 33). Two types of molded foams were also prepared
targeting density of 3.5 pcf (.about.56 kg/m.sup.3). Both foams
based on 20% polyol 74-176 (Designation 6B in Table Ex3-8A) and 15%
polyol 80-148 (Designation 7B in Table Ex3-10) exhibited higher CFD
properties and higher tensile and tear strength in comparison to
the foams prepared at lower densities. More importantly, both foams
exhibited lower hysteresis loss and lower wet and dry compression
set (Tables Ex3-8A and Ex3-10).
V. Conclusions
[0355] Introduction of the four different Novomer polyols into
reference foam formulation as drop-in replacement for Poly-G 85-29
and Voranol Voractiv 6340 did not significantly affect the reaction
profile (foaming profile) measured as cream time, gel time, and
rise time.
[0356] The density and apparent cell structure of the free-rise
foams did not change significantly with a drop-in replacement of
Poly-G 85-29 and Voranol Voractiv 6340 polyols with Novomer
polyols.
[0357] The apparent cell structure of molded foams prepared with
Novomer polyols was uniform and similar to the reference foams
prepared with and without the graft polyol.
[0358] All foams prepared with Novomer polyols exhibited relatively
high resilience and relatively low hysteresis loss and thus can be
classified as High Resilient (HR) PU foams.
[0359] The tensile strength and tear strength properties of foams
prepared with Novomer polyols were somewhat better in comparison to
the reference foams.
[0360] Results of CFD measurements clearly indicate an increase in
load bearing properties of molded foams based on Novomer polyols
without significant effect on the SAG (comfort) factor.
[0361] Foams based on Novomer polyols exhibited some increase in
wet and dry compression set in comparison to the reference foams.
However, all molded foams prepared with Novomer polyols met the wet
compression set requirements of 25% maximum defined by the Chrysler
Material Standard for Type IV foams.
[0362] Practically all molded foams based on Novomer polyols met
the hysteresis loss, tear resistance, and wet compression
requirements specified by the Chrysler Material Standard: MS-DC-649
for "Cellular, Molded Polyurethane High Resilient (HR) Type Seat
Applications" (FIG. 33).
[0363] The flammability of molded foams was not affected by
addition of Novomer polyols.
Other Embodiments
[0364] The foregoing has been a description of certain non-limiting
embodiments of the invention. Accordingly, it is to be understood
that the embodiments of the invention herein described are merely
illustrative of the application of the principles of the invention.
Reference herein to details of the illustrated embodiments is not
intended to limit the scope of the claims, which themselves recite
those features regarded as essential to the invention.
Appendix a Aliphatic Polycarbonate Polyols
[0365] This section describes some of the aliphatic polycarbonate
polyols that have utility in methods and compositions of the
present invention. Aliphatic polycarbonate polyols referred to
herein are derived from the copolymerization of one or more
epoxides and carbon dioxide. Examples of suitable polyols, as well
as methods of making them are disclosed in PCT publication
WO2010/028362 the entirety of which is incorporated herein by
reference.
[0366] It is advantageous for many of the embodiments described
herein that the aliphatic polycarbonate polyols used have a high
percentage of reactive end groups. Such reactive end-groups are
typically hydroxyl groups, but other reactive functional groups may
be present if the polyols are treated to modify the chemistry of
the end groups. Such modified materials may terminate in amino
groups, thiol groups, alkene groups, carboxylate groups, silanes,
phosphate derivatives, isocyanate groups and the like. For purposes
of this invention, the term `aliphatic polycarbonate polyol`
typically refers to --OH terminated materials, but the
incorporation of end-group modified compositions is not excluded,
unless otherwise specified.
[0367] In certain embodiments, at least 90% of the end groups of
the polycarbonate polyol used are reactive groups. In certain
embodiments, at least 95%, at least 96%, at least 97% or at least
98% of the end groups of the polycarbonate polyol used are reactive
groups. In certain embodiments, more than 99%, more than 99.5%,
more than 99.7%, or more than 99.8% of the end groups of the
polycarbonate polyol used are reactive groups. In certain
embodiments, more than 99.9% of the end groups of the polycarbonate
polyol used are reactive groups.
[0368] In certain embodiments, at least 90% of the end groups of
the polycarbonate polyol used are --OH groups. In certain
embodiments, at least 95%, at least 96%, at least 97% or at least
98% of the end groups of the polycarbonate polyol used are --OH
groups. In certain embodiments, more than 99%, more than 99.5%,
more than 99.7%, or more than 99.8% of the end groups of the
polycarbonate polyol used are --OH groups. In certain embodiments,
more than 99.9% of the end groups of the polycarbonate polyol used
are --OH groups.
[0369] Another way of expressing the --OH end-group content of a
polyol composition is by reporting its OH# which is measured using
methods well known in the art. In certain embodiments, the
aliphatic polycarbonate polyols utilized in the present invention
have an OH# greater than about 40. In certain embodiments, the
aliphatic polycarbonate polyols have an OH# greater than about 50,
greater than about 75, greater than about 100, or greater than
about 120.
[0370] In certain embodiments, it is advantageous if the aliphatic
polycarbonate polyol compositions have a substantial proportion of
primary hydroxyl end groups. These are the norm for compositions
comprising poly(ethylene carbonate), but for polyols derived
copolymerization of substituted epoxides, it is common for some or
most of the chain ends to consist of secondary hydroxyl groups.
Poly(propylene carbonate) polyol is one example of a polyol that
may have mostly secondary hydroxyl end groups. In certain
embodiments, such polyols are treated to increase the proportion of
primary --OH end groups. This may be accomplished by methods known
in the art such as by reacting the secondary hydroxyl groups with
reagents such as ethylene oxide, reactive lactones, and the like.
In certain embodiments, the aliphatic polycarbonate polyols are
treated with beta lactones, caprolactone and the like to introduce
primary hydroxyl end groups. In certain embodiments, the aliphatic
polycarbonate polyols are treated with ethylene oxide to introduce
primary hydroxyl end groups.
[0371] In certain embodiments, polycarbonate polyols with utility
for the present invention contain a primary repeating unit having a
structure:
##STR00018##
where R.sup.1, R.sup.2, R.sup.3, and R.sup.4 are, at each
occurrence in the polymer chain, independently selected from the
group consisting of --H, fluorine, an optionally substituted
C.sub.1-40 aliphatic group, an optionally substituted C.sub.1-20
heteroaliphatic group, and an optionally substituted aryl group,
where any two or more of R.sup.1, R.sup.2, R.sup.3, and R.sup.4 may
optionally be taken together with intervening atoms to form one or
more optionally substituted rings optionally containing one or more
heteroatoms.
[0372] In certain embodiments, polycarbonate polyols with utility
for the present invention contain a primary repeating unit having a
structure:
##STR00019## [0373] where R.sup.1 is as defined above and in the
classes, subclasses and examples herein.
[0374] In certain embodiments, aliphatic polycarbonate chains
comprise a copolymer of carbon dioxide and ethylene oxide. In
certain embodiments, aliphatic polycarbonate chains comprise a
copolymer of carbon dioxide and propylene oxide. In certain
embodiments, aliphatic polycarbonate chains comprise a copolymer of
carbon dioxide and cyclohexene oxide. In certain embodiments,
aliphatic polycarbonate chains comprise a copolymer of carbon
dioxide and cyclopentene oxide. In certain embodiments, aliphatic
polycarbonate chains comprise a copolymer of carbon dioxide and
3-vinyl cyclohexane oxide.
[0375] In certain embodiments, aliphatic polycarbonate chains
comprise a terpolymer of carbon dioxide and ethylene oxide along
with one or more additional epoxides selected from the group
consisting of propylene oxide, 1,2-butene oxide, 2,3-butene oxide,
cyclohexene oxide, 3-vinyl cyclohexene oxide, epichlorohydrin,
glicydyl esters, glycidyl ethers, styrene oxides, and epoxides of
higher alpha olefins. In certain embodiments, such terpolymers
contain a majority of repeat units derived from ethylene oxide with
lesser amounts of repeat units derived from one or more additional
epoxides. In certain embodiments, terpolymers contain about 50% to
about 99.5% ethylene oxide-derived repeat units. In certain
embodiments, terpolymers contain greater than about 60% ethylene
oxide-derived repeat units. In certain embodiments, terpolymers
contain greater than 75% ethylene oxide-derived repeat units. In
certain embodiments, terpolymers contain greater than 80% ethylene
oxide-derived repeat units. In certain embodiments, terpolymers
contain greater than 85% ethylene oxide-derived repeat units. In
certain embodiments, terpolymers contain greater than 90% ethylene
oxide-derived repeat units. In certain embodiments, terpolymers
contain greater than 95% ethylene oxide-derived repeat units.
[0376] In some embodiments, aliphatic polycarbonate chains comprise
a copolymer of carbon dioxide and propylene oxide along with one or
more additional epoxides selected from the group consisting of
ethylene oxide, 1,2-butene oxide, 2,3-butene oxide, cyclohexene
oxide, 3-vinyl cyclohexene oxide, epichlorohydrin, glicydyl esters,
glycidyl ethers, styrene oxides, and epoxides of higher alpha
olefins. In certain embodiments, such terpolymers contain a
majority of repeat units derived from propylene oxide with lesser
amounts of repeat units derived from one or more additional
epoxides. In certain embodiments, terpolymers contain about 50% to
about 99.5% propylene oxide-derived repeat units. In certain
embodiments, terpolymers contain greater than 60% propylene
oxide-derived repeat units. In certain embodiments, terpolymers
contain greater than 75% propylene oxide-derived repeat units. In
certain embodiments, terpolymers contain greater than 80% propylene
oxide-derived repeat units. In certain embodiments, terpolymers
contain greater than 85% propylene oxide-derived repeat units. In
certain embodiments, terpolymers contain greater than 90% propylene
oxide-derived repeat units. In certain embodiments, terpolymers
contain greater than 95% propylene oxide-derived repeat units.
[0377] In certain embodiments, aliphatic polycarbonate compositions
with utility in the present invention have a number average
molecular weight (M.sub.n) in the range of about 500 g/mol to about
25,000 g/mol.
[0378] In certain embodiments, aliphatic polycarbonate chains have
an M.sub.n less than about 25,000 g/mol. In certain embodiments,
aliphatic polycarbonate chains have an M.sub.n less than about
10,000 g/mol. In certain embodiments, aliphatic polycarbonate
chains have an M.sub.n less than about 5,000 g/mol. In certain
embodiments, aliphatic polycarbonate chains have an M.sub.n between
about 500 g/mol and about 15,000 g/mol. In certain embodiments,
aliphatic polycarbonate chains have an M.sub.n between about 500
g/mol and about 10,000 g/mol. In certain embodiments, aliphatic
polycarbonate chains have an M.sub.n between about 500 g/mol and
about 5,000 g/mol. In certain embodiments, aliphatic polycarbonate
chains have an M.sub.n between about 500 g/mol and about 3,000
g/mol. In certain embodiments, aliphatic polycarbonate chains have
an M.sub.n between about 500 g/mol and about 2,500 g/mol. In
certain embodiments, aliphatic polycarbonate chains have an M.sub.n
between about 500 g/mol and about 2,000 g/mol. In certain
embodiments, aliphatic polycarbonate chains have an M.sub.n between
about 500 g/mol and about 1,500 g/mol. In certain embodiments,
aliphatic polycarbonate chains have an M.sub.n between about 500
g/mol and about 1,000 g/mol. In certain embodiments, aliphatic
polycarbonate chains have an M.sub.n between about 1,000 g/mol and
about 5,000 g/mol. In certain embodiments, aliphatic polycarbonate
chains have an M.sub.n between about 1.000 g/mol and about 3,000
g/mol. In certain embodiments, aliphatic polycarbonate chains have
an M.sub.n between about 5,000 g/mol and about 10,000 g/mol. In
certain embodiments, aliphatic polycarbonate chains have an M.sub.n
of about 5,000 g/mol. In certain embodiments, aliphatic
polycarbonate chains have an M.sub.n of about 4,000 g/mol. In
certain embodiments, aliphatic polycarbonate chains have an M.sub.n
of about 3,000 g/mol. In certain embodiments, aliphatic
polycarbonate chains have an M.sub.n of about 2,500 g/mol. In
certain embodiments, aliphatic polycarbonate chains have an M.sub.n
of about 2,000 g/mol. In certain embodiments, aliphatic
polycarbonate chains have an M.sub.n of about 1,500 g/mol. In
certain embodiments, aliphatic polycarbonate chains have an M.sub.n
of about 1,000 g/mol. In certain embodiments, aliphatic
polycarbonate chains have an M.sub.n of about 850 g/mol. In certain
embodiments, aliphatic polycarbonate chains have an M.sub.n of
about 750 g/mol. In certain embodiments, aliphatic polycarbonate
chains have an M.sub.n of about 500 g/mol.
[0379] In certain embodiments, the aliphatic polycarbonate polyols
used are characterized in that they have a narrow molecular weight
distribution. This can be indicated by the polydispersity indices
(PDI) of the aliphatic polycarbonate polymers. In certain
embodiments, aliphatic polycarbonate compositions have a PDI less
than 2. In certain embodiments, aliphatic polycarbonate
compositions have a PDI less than 1.8. In certain embodiments,
aliphatic polycarbonate compositions have a PDI less than 1.5. In
certain embodiments, aliphatic polycarbonate compositions have a
PDI less than 1.4. In certain embodiments, aliphatic polycarbonate
compositions have a PDI between about 1.0 and 1.2. In certain
embodiments, aliphatic polycarbonate compositions have a PDI
between about 1.0 and 1.1.
[0380] In certain embodiments aliphatic polycarbonate compositions
of the present invention comprise substantially alternating
polymers containing a high percentage of carbonate linkages and a
low content of ether linkages. In certain embodiments, aliphatic
polycarbonate compositions of the present invention are
characterized in that, on average in the composition, the
percentage of carbonate linkages is 85% or greater. In certain
embodiments, aliphatic polycarbonate compositions of the present
invention are characterized in that, on average in the composition,
the percentage of carbonate linkages is 90% or greater. In certain
embodiments, aliphatic polycarbonate compositions of the present
invention are characterized in that, on average in the composition,
the percentage of carbonate linkages is 91% or greater. In certain
embodiments, aliphatic polycarbonate compositions of the present
invention are characterized in that, on average in the composition,
the percentage of carbonate linkages is 92% or greater. In certain
embodiments, aliphatic polycarbonate compositions of the present
invention are characterized in that, on average in the composition,
the percentage of carbonate linkages is 93% or greater. In certain
embodiments, aliphatic polycarbonate compositions of the present
invention are characterized in that, on average in the composition,
the percentage of carbonate linkages is 94% or greater. In certain
embodiments, aliphatic polycarbonate compositions of the present
invention are characterized in that, on average in the composition,
the percentage of carbonate linkages is 95% or greater. In certain
embodiments, aliphatic polycarbonate compositions of the present
invention are characterized in that, on average in the composition,
the percentage of carbonate linkages is 96% or greater. In certain
embodiments, aliphatic polycarbonate compositions of the present
invention are characterized in that, on average in the composition,
the percentage of carbonate linkages is 97% or greater. In certain
embodiments, aliphatic polycarbonate compositions of the present
invention are characterized in that, on average in the composition,
the percentage of carbonate linkages is 98% or greater. In certain
embodiments, aliphatic polycarbonate compositions of the present
invention are characterized in that, on average in the composition,
the percentage of carbonate linkages is 99% or greater. In certain
embodiments, aliphatic polycarbonate compositions of the present
invention are characterized in that, on average in the composition,
the percentage of carbonate linkages is 99.5% or greater. In
certain embodiments, the percentages above exclude ether linkages
present in polymerization initiators or chain transfer agents and
refer only to the linkages formed during epoxide CO.sub.2
copolymerization.
[0381] In certain embodiments, aliphatic polycarbonate compositions
of the present invention are characterized in that they contain
essentially no ether linkages either within the polymer chains
derived from epoxide CO.sub.2 copolymerization or within any
polymerization intiators, chain transfer agents or end groups that
may be present in the polymer. In certain embodiments, aliphatic
polycarbonate compositions of the present invention are
characterized in that they contain, on average, less than one ether
linkage per polymer chain within the composition. In certain
embodiments, aliphatic polycarbonate compositions of the present
invention are characterized in that they contain essentially no
ether linkages
[0382] In certain embodiments where an aliphatic polycarbonate is
derived from monosubstituted epoxides (e.g. such as propylene
oxide, 1,2-butylene oxide, epichlorohydrin, epoxidized alpha
olefins, or a glycidol derivative), the aliphatic polycarbonate is
characterized in that it is regioregular. Regioregularity may be
expressed as the percentage of adjacent monomer units that are
oriented in a head-to-tail arrangement within the polymer chain. In
certain embodiments, aliphatic polycarbonate chains in the
inventive polymer compositions have a head-to-tail content higher
than about 80%. In certain embodiments, the head-to-tail content is
higher than about 85%. In certain embodiments, the head-to-tail
content is higher than about 90%. In certain embodiments, the
head-to-tail content is greater than about 91%, greater than about
92%, greater than about 93%, greater than about 94%, or greater
than about 95%. In certain embodiments, the head-to-tail content of
the polymer is as determined by proton or carbon-13 NMR
spectroscopy.
[0383] In certain embodiments, aliphatic polycarbonate polyols
useful for the present invention have a viscosity controlled to be
within a particular range. The preferred range may depend upon a
particular application and may be controlled to be within the
normal range for a particular application.
[0384] In certain embodiments, where the aliphatic polycarbonate
polyol is used in the formulation of a rigid foam or a
thermoplastic composition, the polyol has a viscosity, as measured
at a temperature of at least 20.degree. C. but less than 70.degree.
C., of less than about 30,000 cps. In certain embodiments, such
polyols have a viscosity less than about 20,000 cps, less than
about 15,000 cps, less than about 12,000 cps, or less than about
10,000 cps. In certain embodiments, such polyols have a viscosity
between about 600 and about 30,000 cps. In certain embodiments,
such polyols have a viscosity between about 2,000 and about 20,000
cps. In certain embodiments, such polyols have a viscosity between
about 5,000 and about 15,000 cps.
[0385] In other embodiments, where the aliphatic polycarbonate
polyol is used in the formulation of a flexible foam, the polyol
has a viscosity, as measured at a temperature of at least
20.degree. C. but less than 70.degree. C., of less than about
10,000 cps. In certain embodiments, such polyols have a viscosity
less than about 8,000 cps, less than about 6,000 cps, less than
about 3,000 cps, or less than about 2,000 cps. In certain
embodiments, such polyols have a viscosity between about 1,000 and
about 10,000 cps. In certain embodiments, such polyols have a
viscosity between about 1,000 and about 6,000 cps.
[0386] In certain embodiments, the polyol viscosity values
described above represent the viscosity as measured at 25.degree.
C. In certain embodiments, the viscosity values above represent the
viscosity as measured at 30.degree. C., 40.degree. C., 50.degree.
C., 60.degree. C. or 70.degree. C.
[0387] In certain embodiments, aliphatic polycarbonate polyols
useful for the present invention have a Tg within a particular
range. The desired Tg will vary with the application and may be
controlled to be within the known normal range for a particular
application. In certain embodiments, where the polyol is used in
the formulation of a flexible foam composition, the polyol has a Tg
less than about 20.degree. C. In certain embodiments, such polyols
have Tg less than about 15.degree. C., less than about 10.degree.
C., less than about 5.degree. C., less than about 0.degree. C.,
less than about -10.degree. C., less than about -20.degree. C., or
less than about 40.degree. C. In certain embodiments, such polyols
have a Tg between about -30.degree. C. and about -20.degree. C. In
certain embodiments, such polyols have a Tg between about
-30.degree. C. and about -20.degree. C.
[0388] In certain embodiments, where the aliphatic polycarbonate
polyol is used in the formulation of a rigid foam composition, the
polyol has a Tg greater than about -30.degree. C. In certain
embodiments, such polyols have Tg greater than about -20.degree.
C., greater than about -10.degree. C., greater than about 0.degree.
C., greater than about 10.degree. C., greater than about 15.degree.
C., or greater than about 25.degree. C. In certain embodiments,
such polyols have a Tg between about -10.degree. C. and about
30.degree. C. In certain embodiments, such polyols have a Tg
between about 0.degree. C. and about 20.degree. C.
[0389] In certain embodiments, compositions of the present
invention comprise aliphatic polycarbonate polyols having a
structure P1:
##STR00020## [0390] wherein,
[0391] R.sup.1, R.sup.2, R.sup.3, and R.sup.4 are, at each
occurrence in the polymer chain, independently selected from the
group consisting of --H, fluorine, an optionally substituted
C.sub.1-30 aliphatic group, and an optionally substituted
C.sub.1-20 heteroaliphatic group, and an optionally substituted
C.sub.6-10 aryl group, where any two or more of R.sup.1, R.sup.2,
R.sup.3, and R.sup.4 may optionally be taken together with
intervening atoms to form one or more optionally substituted rings
optionally containing one or more heteroatoms;
[0392] Y is, at each occurrence, independently --H or the site of
attachment of a moiety containing another reactive end group such
as those described hereinabove;
[0393] n is at each occurrence, independently an integer from about
2 to about 100;
##STR00021##
is a multivalent moiety; and
[0394] x and y are each independently an integer from 0 to 6, where
the sum of x and y is between 2 and 6.
[0395] In certain embodiments, the multivalent moiety
##STR00022##
embedded within the aliphatic polycarbonate chain is derived from a
polyfunctional chain transfer agent having two or more sites from
which epoxide/CO.sub.2 copolymerization can occur. In certain
embodiments, such copolymerizations are performed in the presence
of polyfunctional chain transfer agents as exemplified in PCT
publication WO/2010/028362.
[0396] In certain embodiments, a polyfunctional chain transfer
agent has a formula:
##STR00023##
[0397] wherein each of
##STR00024##
x, and y is as defined above and described in classes and
subclasses herein.
[0398] In certain embodiments, aliphatic polycarbonate chains in
the inventive polymer compositions are derived from the
copolymerization of one or more epoxides with carbon dioxide in the
presence of such polyfunctional chain transfer agents as shown in
Scheme 2:
##STR00025##
[0399] In certain embodiments, aliphatic polycarbonate chains in
polymer compositions of the present invention comprise chains with
a structure P2:
##STR00026##
[0400] wherein each of R.sup.1. R.sup.2, R.sup.3, R.sup.4, Y,
##STR00027##
and n is as defined above and described in the classes and
subclasses herein.
[0401] In certain embodiments where aliphatic polycarbonate chains
have a structure P2,
##STR00028##
is derived from a dihydric alcohol. In such instances
##STR00029##
represents the carbon-containing backbone of the dihydric alcohol,
while the two oxygen atoms adjacent to
##STR00030##
are derived from the --OH groups of the diol. For example, if the
polyfunctional chain transfer agent were ethylene glycol, then
##STR00031##
would be --CH.sub.2CH.sub.2-- and P2 would have the following
structure:
##STR00032##
[0402] It will be apparent to the skilled artisan, that this is the
case for the other polyfunctional chain transfer agents described
herein--there is a nexus between the structure of the chain
transfer agent employed and the structure of
##STR00033##
in the resulting polyol.
[0403] In certain embodiments, where
##STR00034##
is derived from a dihydric alcohol, the dihydric alcohol comprises
a C.sub.2-40 diol. In certain embodiments, the dihydric alcohol is
selected from the group consisting of: 1,2-ethanediol,
1,2-propanediol, 1,3-propanediol, 1,2-butanediol, 1,3-butanediol,
1,4-butanediol, 1,5-pentanediol, 2,2-dimethylpropane-1,3-diol,
2-butyl-2-ethylpropane-1,3-diol, 2-methyl-2,4-pentane diol,
2-ethyl-1,3-hexane diol, 2-methyl-1,3-propane diol, 1,5-hexanediol,
1,6-hexanediol, 1,8-octanediol, 1,10-decanediol, 1,12-dodecanediol,
2,2,4,4-tetramethylcyclobutane-1,3-diol, 1,3-cyclopentanediol,
1,2-cyclohexanediol, 1,3-cyclohexanediol, 1,4-cyclohexanediol,
1,2-cyclohexanedimethanol, 1,3-cyclohexanedimethanol,
1,4-cyclohexanedimethanol, 1,4-cyclohexanediethanol, isosorbide,
glycerol monoesters, glycerol monoethers, trimethylolpropane
monoesters, trimethylolpropane monoethers, pentaerythritol
diesters, pentaerythritol diethers, and alkoxylated derivatives of
any of these.
[0404] In certain embodiments, where
##STR00035##
is derived from a dihydric alcohol, the dihydric alcohol is
selected from the group consisting of: diethylene glycol,
triethylene glycol, tetraethylene glycol, higher poly(ethylene
glycol), such as those having number average molecular weights of
from 220 to about 2000 g/mol, dipropylene glycol, tripropylene
glycol, and higher poly(propylene glycols) such as those having
number average molecular weights of from 234 to about 2000
g/mol.
[0405] In certain embodiments, where
##STR00036##
is derived from a dihydric alcohol, the dihydric alcohol comprises
an alkoxylated derivative of a compound selected from the group
consisting of: a diacid, a diol, or a hydroxy acid. In certain
embodiments, the alkoxylated derivatives comprise ethoxylated or
propoxylated compounds.
[0406] In certain embodiments, where
##STR00037##
is derived from a dihydric alcohol, the dihydric alcohol comprises
a polymeric diol. In certain embodiments, a polymeric diol is
selected from the group consisting of polyethers, polyesters,
hydroxy-terminated polyolefins, polycarbonate polyols derived from
diols and phosgene (or its reactive equivalents);
polyether-copolyesters, polyether polycarbonates,
polycarbonate-copolyesters, polyoxymethylene polymers, and
alkoxylated analogs of any of these. In certain embodiments, the
polymeric diol has an average molecular weight less than about 2000
g/mol.
[0407] In certain embodiments,
##STR00038##
is derived from a polyhydric alcohol with more than two hydroxy
groups. In certain embodiments, the aliphatic polycarbonate chains
in polymer compositions of the present invention comprise aliphatic
polycarbonate chains where the moiety
##STR00039##
is derived from a triol. In certain embodiments, such aliphatic
polycarbonate chains have the structure P3:
##STR00040##
[0408] wherein each of R.sup.1, R.sup.2, R.sup.3, R.sup.4, Y,
##STR00041##
and n is as defined above and described in classes and subclasses
herein.
[0409] In certain embodiments where
##STR00042##
is derived from a triol, the triol is selected from the group
consisting of: glycerol, 1,2,4-butanetriol,
2-(hydroxymethyl)-1,3-propanediol; hexane triols, trimethylol
propane, trimethylol ethane, trimethylolhexane,
1,4-cyclohexanetrimethanol, pentaerythritol mono esters,
pentaerythritol mono ethers, and alkoxylated analogs of any of
these. In certain embodiments, alkoxylated derivatives comprise
ethoxylated or propoxylated compounds.
[0410] In certain embodiments,
##STR00043##
is derived from an alkoxylated derivative of a trifunctional
carboxylic acid or trifunctional hydroxy acid. In certain
embodiments, alkoxylated derivatives comprise ethoxylated or
propoxylated compounds.
[0411] In certain embodiments, where
##STR00044##
is derived from a polymeric triol, the polymeric triol is selected
from the group consisting of polyethers, polyesters,
hydroxy-terminated polyolefins, polyether-copolyesters, polyether
polycarbonates, polyoxymethylene polymers,
polycarbonate-copolyesters, and alkoxylated analogs of any of
these. In certain embodiments, the alkoxylated polymeric triols
comprise ethoxylated or propoxylated compounds.
[0412] In certain embodiments,
##STR00045##
is derived from a polyhydric alcohol with four hydroxy groups. In
certain embodiments, aliphatic polycarbonate chains in polymer
compositions of the present invention comprise aliphatic
polycarbonate chains where the moiety
##STR00046##
is derived from a tetraol. In certain embodiments, aliphatic
polycarbonate chains in polymer compositions of the present
invention comprise chains with the structure P4:
##STR00047##
[0413] wherein each of R.sup.1, R.sup.2, R.sup.3, R.sup.4, Y,
##STR00048##
and n is as defined above and described in classes and subclasses
herein.
[0414] In certain embodiments,
##STR00049##
is derived from a polyhydric alcohol with more than four hydroxy
groups. In certain embodiments,
##STR00050##
is derived from a polyhydric alcohol with six hydroxy groups. In
certain embodiments, a polyhydric alcohol is dipentaerithrotol or
an alkoxylated analog thereof. In certain embodiments, a polyhydric
alcohol is sorbitol or an alkoxylated analog thereof. In certain
embodiments, aliphatic polycarbonate chains in polymer compositions
of the present invention comprise chains with the structure P5:
##STR00051##
[0415] wherein each of R.sup.1, R.sup.2, R.sup.3, R.sup.4, Y,
##STR00052##
and n is as defined above and described in classes and subclasses
herein.
[0416] In certain embodiments, aliphatic polycarbonates of the
present invention comprise a combination of bifunctional chains
(e.g. polycarbonates of formula P2) in combination with higher
functional chains (e.g. one or more polycarbonates of formulae P3
to P5).
[0417] In certain embodiments,
##STR00053##
is derived from a hydroxy acid. In certain embodiments, aliphatic
polycarbonate chains in polymer compositions of the present
invention comprise chains with the structure P6:
##STR00054##
[0418] wherein each of R.sup.1, R.sup.2, R.sup.3, R.sup.4, Y,
##STR00055##
and n is as defined above and described in classes and subclasses
herein. In such instances,
##STR00056##
represents the carbon-containing backbone backbone of the hydroxy
acid, while the ester and carbonate linkages adjacent to
##STR00057##
are derived from the --CO.sub.2H group and the hydroxy group of the
hydroxy acid. For example, if
##STR00058##
were derived from 3-hydroxy propanoic acid, then
##STR00059##
would be --CH.sub.2CH.sub.2-- and P6 would have the following
structure:
##STR00060##
[0419] In certain embodiments,
##STR00061##
is derived from an optionally substituted C.sub.2-40 hydroxy acid.
In certain embodiments,
##STR00062##
is derived from a polyester. In certain embodiments, such
polyesters have a molecular weight less than about 2000 g/mol.
[0420] In certain embodiments, a hydroxy acid is an alpha-hydroxy
acid. In certain embodiments, a hydroxy acid is selected from the
group consisting of: glycolic acid, DL-lactic acid, D-lactic acid,
L-lactic, citric acid, and mandelic acid.
[0421] In certain embodiments, a hydroxy acid is a beta-hydroxy
acid. In certain embodiments, a hydroxy acid is selected from the
group consisting of: 3-hydroxypropionic acid, DL 3-hydroxybutryic
acid, D-3 hydroxybutryic acid, L-3-hydroxybutyric acid,
DL-3-hydroxy valeric acid, D-3-hydroxy valeric acid, L-3-hydroxy
valeric acid, salicylic acid, and derivatives of salicylic
acid.
[0422] In certain embodiments, a hydroxy acid is a .alpha.-.omega.
hydroxy acid. In certain embodiments, a hydroxy acid is selected
from the group consisting of: of optionally substituted C.sub.3-20
aliphatic .alpha.-.omega. hydroxy acids and oligomeric esters.
[0423] In certain embodiments, a hydroxy acid is selected from the
group consisting of:
##STR00063## ##STR00064##
[0424] In certain embodiments,
##STR00065##
is derived from a polycarboxylic acid. In certain embodiments,
aliphatic polycarbonate chains in polymer compositions of the
present invention comprise chains with the structure P7:
##STR00066##
wherein each of R.sup.1, R.sup.2, R.sup.3, R.sup.4, Y,
##STR00067##
and n is as defined above and described in classes and subclasses
herein, and y' is an integer from 1 to 5 inclusive.
[0425] In embodiments where the aliphatic polycarbonate chains have
a structure P7,
##STR00068##
represents the carbon-containing backbone (or a covalent bond in
the case of oxalic acid) of a polycarboxylic acid, while ester
groups adjacent to
##STR00069##
are derived from --CO.sub.2H groups of the polycarboxylic acid. For
example, if
##STR00070##
were derived from succinic acid
(HO.sub.2CCH.sub.2CH.sub.2CO.sub.2H), then
##STR00071##
would be --CH.sub.2CH.sub.2-- and P7 would have the following
structure:
##STR00072##
wherein each of R.sup.1, R.sup.2, R.sup.3, R.sup.4, Y, and n is as
defined above and described in classes and subclasses herein.
[0426] In certain embodiments,
##STR00073##
is derived from a dicarboxylic acid. In certain embodiments,
aliphatic polycarbonate chains in polymer compositions of the
present invention comprise chains with the structure P8:
##STR00074##
[0427] In certain embodiments,
##STR00075##
is selected from the group consisting of: phthalic acid,
isophthalic acid, terephthalic acid, maleic acid, succinic acid,
malonic acid, glutaric acid, adipic acid, pimelic acid, suberic
acid, and azelaic acid.
[0428] In certain embodiments,
##STR00076##
is selected from the group consisting of:
##STR00077## ##STR00078##
[0429] In certain embodiments, each
##STR00079##
in the structures herein is independently selected from the group
consisting of:
##STR00080## ##STR00081## [0430] wherein each R.sup.x is
independently an optionally substituted group selected from the
group consisting of C.sub.2-20 aliphatic, C.sub.2-20
heteroaliphatic, 3- to 14-membered carbocyclic, 6-to 10-membered
aryl. 5- to 10-membered heteroaryl, and 3- to 12-membered
heterocyclic.
[0431] In certain embodiments, each
##STR00082##
in the structures herein is independently selected from the group
consisting of:
##STR00083## [0432] wherein R.sup.x is as defined above and
described in classes and subclasses herein.
[0433] In certain embodiments, aliphatic polycarbonate chains
comprise:
##STR00084## [0434] wherein each of
##STR00085##
[0434] -Y, and n is as defined above and described in classes and
subclasses herein.
[0435] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00086## [0436] wherein each of -Y and n is as defined above
and described in classes and subclasses herein.
[0437] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00087## [0438] wherein each of -Y and n is as defined above
and described in classes and subclasses herein.
[0439] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00088## [0440] wherein each of -Y and n is as defined above
and described in classes and subclasses herein.
[0441] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00089##
wherein each of -Y and n is as defined above and described in
classes and subclasses herein.
[0442] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00090##
wherein each of
##STR00091##
, --Y, and n is as defined above and described in classes and
subclasses herein.
[0443] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00092##
wherein each of -Y and n is as defined above and described in
classes and subclasses herein.
[0444] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00093##
wherein each of -Y and n is as defined above and described in
classes and subclasses herein.
[0445] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00094## [0446] wherein each of -Y and n is as defined above
and described in classes and subclasses herein.
[0447] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00095## [0448] wherein each of
##STR00096##
[0448] --Y, and n is as defined above and described in classes and
subclasses herein.
[0449] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00097## [0450] wherein each of -Y and n are is as defined
above and described in classes and subclasses herein.
[0451] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00098## [0452] wherein each of
##STR00099##
[0452] -Y, and n is as defined above and described in classes and
subclasses herein.
[0453] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00100## [0454] wherein each of -Y and n is as defined above
and described in classes and subclasses herein.
[0455] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00101## [0456] wherein each of
##STR00102##
[0456] -Y and n is as defined above and described in classes and
subclasses herein.
[0457] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00103## [0458] wherein each of -Y and n is as defined above
and described in classes and subclasses herein.
[0459] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00104## [0460] wherein each of
##STR00105##
[0460] --Y, R.sup.x, and n is as defined above and described in
classes and subclasses herein.
[0461] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00106## [0462] wherein each of -Y, R.sup.x, and n is as
defined above and described in classes and subclasses herein.
[0463] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00107## [0464] wherein each of
##STR00108##
[0464] -Y, and n is as defined above and described in classes and
subclasses herein.
[0465] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00109## [0466] wherein each of
##STR00110##
[0466] -Y, and n are is as defined above and described in classes
and subclasses herein; and each independently represents a single
or double bond.
[0467] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00111## [0468] wherein each of -Y and n is as defined above
and described in classes and subclasses herein.
[0469] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00112## [0470] wherein each of -Y, , and n is as defined above
and described in classes and subclasses herein.
[0471] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00113## [0472] wherein each of
##STR00114##
[0472] R.sup.x, --Y and n is as defined above and described in
classes and subclasses herein.
[0473] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00115## [0474] wherein each of -Y, R.sup.x, and n is as
defined above and described in classes and subclasses herein.
[0475] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00116## [0476] wherein each of
##STR00117##
[0476] -Y, and n is as defined above and described in classes and
subclasses herein.
[0477] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00118## [0478] wherein each of -Y, , and n is as defined above
and described in classes and subclasses herein.
[0479] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00119## [0480] wherein each of -Y and n is as defined above
and described in classes and subclasses herein.
[0481] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00120## [0482] wherein each of -Y, , and n is as defined above
and described in classes and subclasses herein.
[0483] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00121## [0484] wherein each of
[0484] ##STR00122## [0485] -Y, and n is as defined above and
described in classes and subclasses herein.
[0486] In certain embodiments, aliphatic polycarbonate chains
comprise
##STR00123## [0487] wherein each of -Y and n is as defined above
and described in classes and subclasses herein.
[0488] In certain embodiments, in polycarbonates of structures P2a,
P2c, P2d, P2f, P2h, P2j. P21, P21-a, P2n P2p and P2n, P2p, and
P2r,
##STR00124##
is selected from the group consisting of: ethylene glycol;
diethylene glycol, triethylene glycol, 1,3 propane diol; 1,4 butane
diol, hexylene glycol, 1,6 hexane diol, propylene glycol,
dipropylene glycol, tripopylene glycol, and alkoxylated derivatives
of any of these.
[0489] For polycarbonates comprising repeat units derived from two
or more epoxides, such as those represented by structures P2f
through P2r, depicted above, it is to be understood that the
structures drawn may represent mixtures of positional isomers or
regioisomers that are not explicitly depicted. For example, the
polymer repeat unit adjacent to either end group of the
polycarbonate chains can be derived from either one of the two
epoxides comprising the copolymers, or from only one of the two
epoxides. Thus, while the polymers may be drawn with a particular
repeat unit attached to an end group, the terminal repeat units
might be derived from either of the two epoxides and a given
polymer composition might comprise a mixture of all of the
possibilities in varying ratios. The ratio of these end-groups can
be influenced by several factors including the ratio of the
different epoxides used in the polymerization, the structure of the
catalyst used, the reaction conditions used (i.e temperature,
CO.sub.2 pressure, etc.) as well as by the timing of addition of
reaction components. Similarly, while the drawings above may show a
defined regiochemistry for repeat units derived from substituted
epoxides, the polymer compositions will, in some cases, contain
mixtures of regioisomers. The regioselectivity of a given
polymerization can be influenced by numerous factors including the
structure of the catalyst used and the reaction conditions
employed. To clarify, this means that the composition represented
by structure P2r above, may contain a mixture of several compounds
as shown in the diagram below. This diagram shows the isomers
graphically for polymer P2r, where the structures below the
depiction of the chain show each regio- and positional isomer
possible for the monomer unit adjacent to the chain transfer agent
and the end groups on each side of the main polymer chain. Each end
group on the polymer may be independently selected from the groups
shown on the left or right while the central portion of the polymer
including the chain transfer agent and its two adjacent monomer
units may be independently selected from the groups shown. In
certain embodiments, the polymer composition comprises a mixture of
all possible combinations of these. In other embodiments, the
polymer composition is enriched in one or more of these.
##STR00125##
[0490] In certain embodiments, the aliphatic polycarbonate polyol
is selected from the group consisting of Q1, Q2, Q3, Q4, Q5, Q6,
and mixtures of any two or more of these.
##STR00126## [0491] wherein, t is an integer from 1 to 12
inclusive, and R.sup.t is independently at each occurrence --H, or
--CH.sub.3.
[0492] In certain embodiments, the aliphatic polycarbonate polyol
is selected from the group consisting of:
[0493] Poly(ethylene carbonate) of formula Q1 having an average
molecular weight number of between about 500 g/mol and about 3,000
g/mol, a polydispersity index less than about 1.25, at least 85%
carbonate linkages, and at least 98% --OH end groups;
[0494] Poly(ethylene carbonate) of formula Q1 having an average
molecular weight number of about 500 g/mol, a polydispersity index
less than about 1.25, at least 85% carbonate linkages, and at least
98% --OH end groups;
[0495] Poly(ethylene carbonate) of formula Q1 having an average
molecular weight number of about 1,000 g/mol, a polydispersity
index less than about 1.25, at least 85% carbonate linkages, and at
least 98% --OH end groups;
[0496] Poly(ethylene carbonate) of formula Q1 having an average
molecular weight number of about 2,000 g/mol, a polydispersity
index less than about 1.25, at least 85% carbonate linkages, and at
least 98% --OH end groups;
[0497] Poly(ethylene carbonate) of formula Q1 having an average
molecular weight number of about 3,000 g/mol, a polydispersity
index less than about 1.25, at least 85% carbonate linkages, and at
least 98% --OH end groups;
[0498] Poly(propylene carbonate) of formula Q2 having an average
molecular weight number of between about 500 g/mol and about 3,000
g/mol, a polydispersity index less than about 1.25, at least 95%
carbonate linkages, and at least 98% --OH end groups;
[0499] Poly(propylene carbonate) of formula Q2 having a number
average molecular weight of about 500 g/mol, a polydispersity index
less than about 1.25, at least 95% carbonate linkages, and at least
98% --OH end groups;
[0500] Poly(propylene carbonate) of formula Q2 having a number
average molecular weight of about 1,000 g/mol, a polydispersity
index less than about 1.25, at least 95% carbonate linkages, and at
least 98% --OH end groups;
[0501] Poly(propylene carbonate) of formula Q2 having a number
average molecular weight of about 2,000 g/mol, a polydispersity
index less than about 1.25, at least 95% carbonate linkages, and at
least 98% --OH end groups;
[0502] Poly(propylene carbonate) of formula Q2 having a number
average molecular weight of about 3,000 g/mol, a polydispersity
index less than about 1.25, at least 95% carbonate linkages, and at
least 98% --OH end groups;
[0503] Poly(ethylene-co-propylene carbonate) of formula Q3 having a
number average molecular weight of between about 500 g/mol and
about 3,000 g/mol, a polydispersity index less than about 1.25, at
least 90% carbonate linkages, and at least 98% --OH end groups;
[0504] Poly(ethylene-co-propylene carbonate) of formula Q3 having a
number average molecular weight of about 500 g/mol, a
polydispersity index less than about 1.25, at least 90% carbonate
linkages, and at least 98% --OH end groups;
[0505] Poly(ethylene-co-propylene carbonate) of formula Q3 having a
number average molecular weight of about 1,000 g/mol, a
polydispersity index less than about 1.25, at least 90% carbonate
linkages, and at least 98% --OH end groups;
[0506] Poly(ethylene-co-propylene carbonate) of formula Q3 having a
number average molecular weight of about 2,000 g/mol (e.g. n is on
average between about 10 and about 11), a polydispersity index less
than about 1.25, at least 90% carbonate linkages, and at least 98%
--OH end groups;
[0507] Poly(ethylene-co-propylene carbonate) of formula Q3 having a
number average molecular weight of about 3,000 g/mol, a
polydispersity index less than about 1.25, at least 95% carbonate
linkages, and at least 98% --OH end groups;
[0508] Poly(ethylene carbonate) of formula Q4 having a number
average molecular weight of between about 500 g/mol and about 3,000
g/mol (e.g. each n is between about 4 and about 16), a
polydispersity index less than about 1.25, at least 95% carbonate
linkages, and at least 98% --OH end groups;
[0509] Poly(ethylene carbonate) of formula Q4 having a number
average molecular weight of about 500 g/mol, a polydispersity index
less than about 1.25, at least 85% carbonate linkages, and at least
98% --OH end groups;
[0510] Poly(ethylene carbonate) of formula Q4 having a number
average molecular weight of about 1,000 g/mol, a polydispersity
index less than about 1.25, at least 85% carbonate linkages, and at
least 98% --OH end groups;
[0511] Poly(ethylene carbonate) of formula Q4 having a number
average molecular weight of about 2,000 g/mol, a polydispersity
index less than about 1.25, at least 85% carbonate linkages, and at
least 98% --OH end groups;
[0512] Poly(ethylene carbonate) of formula Q4 having a number
average molecular weight of about 3,000 g/mol, a polydispersity
index less than about 1.25, at least 85% carbonate linkages, and at
least 98% --OH end groups.
[0513] Poly(propylene carbonate) of formula Q5 having a number
average molecular weight of between about 500 g/mol and about 3,000
g/mol, a polydispersity index less than about 1.25, at least 95%
carbonate linkages, and at least 98% --OH end groups;
[0514] Poly(propylene carbonate) of formula Q5 having a number
average molecular weight of about 500 g/mol, a polydispersity index
less than about 1.25, at least 95% carbonate linkages, and at least
98% --OH end groups;
[0515] Poly(propylene carbonate) of formula Q5 having a number
average molecular weight of about 1,000 g/mol, a polydispersity
index less than about 1.25, at least 95% carbonate linkages, and at
least 98% --OH end groups;
[0516] Poly(propylene carbonate) of formula Q5 having a number
average molecular weight of about 2,000 g/mol, a polydispersity
index less than about 1.25, at least 95% carbonate linkages, and at
least 98% --OH end groups;
[0517] Poly(propylene carbonate) of formula Q5 having a number
average molecular weight of about 3,000 g/mol, a polydispersity
index less than about 1.25, at least 95% carbonate linkages, and at
least 98% --OH end groups;
[0518] Poly(ethylene-co-propylene carbonate) of formula Q6 having a
number average molecular weight of between about 500 g/mol and
about 3,000 g/mol, a polydispersity index less than about 1.25, at
least 90% carbonate linkages, and at least 98% --OH end groups;
[0519] Poly(ethylene-co-propylene carbonate) of formula Q6 having a
number average molecular weight of about 500 g/mol, a
polydispersity index less than about 1.25, at least 90% carbonate
linkages, and at least 98% --OH end groups;
[0520] Poly(ethylene-co-propylene carbonate) of formula Q6 having a
number average molecular weight of about 1,000 g/mol, a
polydispersity index less than about 1.25, at least 90% carbonate
linkages, and at least 98% --OH end groups;
[0521] Poly(ethylene-co-propylene carbonate) of formula Q6 having a
number average molecular weight of about 2,000 g/mol (e.g. n is on
average between about 10 and about 11), a polydispersity index less
than about 1.25, at least 90% carbonate linkages, and at least 98%
--OH end groups; and
[0522] Poly(ethylene-co-propylene carbonate) of formula Q6 having a
number average molecular weight of about 3,000 g/mol, a
polydispersity index less than about 1.25, at least 95% carbonate
linkages, and at least 98% --OH end groups.
[0523] In certain embodiments, the embedded chain transfer
agent
##STR00127##
is a moiety derived from a polymeric diol or higher polyhydric
alcohol. In certain embodiments such polymeric alcohols are
polyether or polyester polyols. In certain embodiments
##STR00128##
is a polyether polyol comprising ethylene glycol or propylene
glycol repeating units (--OCH.sub.2CH.sub.2O--, or
--OCH.sub.2CH(CH.sub.3)O--) or combinations of these. In certain
embodiments,
##STR00129##
is a polyester polyol comprising the reaction product of a diol and
a diacid, or a material derived from ring-opening polymerization of
lactones.
[0524] In certain embodiments where
##STR00130##
comprises a polyether diol, the aliphatic polycarbonate polyol has
a structure Q7:
##STR00131## [0525] wherein, [0526] R.sup.q is at each occurrence
in the polymer chain independently --H or --CH.sub.3; [0527]
R.sup.a is --H, or --CH.sub.3; [0528] q and q' are independently an
integer from about 2 to about 40; and [0529] and n is as defined
above and in the examples and embodiments herein.
[0530] In certain embodiments, an aliphatic polycarbonate polyol is
selected from the group consisting of:
##STR00132## [0531] wherein each of R.sup.a, R.sup.q, q, q', and n
is as defined above and described in classes and subclasses
herein.
[0532] In certain embodiments, where aliphatic polycarbonate
polyols comprise compounds conforming to structure Q7, the
moiety
##STR00133##
is derived from a commercially available polyether polyol such as
those typically used in the formulation of polyurethane foam
compositions.
[0533] In certain embodiments where
##STR00134##
comprises a polyester diol, the aliphatic polycarbonate polyol has
a structure Q8:
##STR00135## [0534] wherein, [0535] c is at each occurrence in the
polymer chain independently an integer from 0 to 6; [0536] d is at
each occurrence in the polymer chain independently an integer from
1 to 11; and [0537] each of R.sup.q, n, q, and q' is as defined
above and described in classes and subclasses herein.
[0538] In certain embodiments, an aliphatic polycarbonate polyol is
selected from the group consisting of:
##STR00136## [0539] wherein each of n and q is as defined above and
described in classes and subclasses herein.
[0540] In certain embodiments, where aliphatic polycarbonate
polyols comprise compounds conforming to structure Q8, the
moiety
##STR00137##
is derived from a commercially available polyester polyol such as
those typically used in the formulation of polyurethane foam
compositions.
Appendix B Isocyanate Reagents
[0541] This section describes some of the polyisocyanates and that
have utility in methods and compositions of the present invention.
Compositions of the present invention comprise isocyanate reagents
or their reaction products. The purpose of these isocyanate
reagents is to react with the reactive end groups on the aliphatic
polycarbonate polyols to form higher molecular weight structures
through chain extension and/or cross-linking.
[0542] The art of polyurethane synthesis is well advanced and a
very large number of isocyanates and related polyurethane
precursors are known in the art and available commercially. While
this section of the specification describes isocyanates suitable
for use in certain embodiments of the present invention, it is to
be understood that it is within the capabilities of one skilled in
the art of polyurethane formulation to use alternative isocyanates
along with the teachings of this disclosure to formulate additional
compositions of matter within the scope of the present invention.
Descriptions of suitable isocyanate compounds and related methods
can be found in: Chemistry and Technology of Polyols for
Polyurethanes Ionescu, Mihail 2005 (ISBN 978-1-84735-035-0), and H.
Ulrich, "Urethane Polymers," Kirk-Othmer Encyclopedia of Chemical
Technology, 1997 the entirety of each of which is incorporated
herein by reference.
[0543] In certain embodiments, the isocyanate reagents comprise two
or more isocyanate groups per molecule. In certain embodiments the
isocyanate reagents are diisocyanates. In other embodiments, the
isocyanate reagents are higher polyisocyanates such as
triisocyanates, tetraisocyanates, isocyanate polymers or oligomers,
and the like. In certain embodiments, the isocyanate reagents are
aliphatic polyisocyanates or derivatives or oligomers of aliphatic
polyisocyanates. In other embodiments, the isocyanates are aromatic
polyisocyanates or derivatives or oligomers of aromatic
polyisocyanates. In certain embodiments, the compositions may
comprise mixtures of any two or more of the above types of
isocyanates.
[0544] In certain embodiments, the isocyanate component used in the
formulation of the novel materials of the present invention have a
functionality of 2 or more. In certain embodiments, the isocyanate
component of the inventive materials comprise a mixture of
diisocyanates and higher isocyanates formulated to achieve a
particular functionality number for a given application. In certain
embodiments, where the inventive composition is a flexible foam or
a soft elastomer, the isocyanate employed has a functionality of
about 2. In certain embodiments, such isocyanates have a
functionality between about 2 and about 2.7. In certain
embodiments, such isocyanates have a functionality between about 2
and about 2.5. In certain embodiments, such isocyanates have a
functionality between about 2 and about 2.3. In certain
embodiments, such isocyanates have a functionality between about 2
and about 2.2.
[0545] In other embodiments, where the inventive composition is a
rigid foam or a thermoplastic, the isocyanate employed has a
functionality greater than 2. In certain embodiments, such
isocyanates have a functionality between about 2.3 and about 4. In
certain embodiments, such isocyanates have a functionality between
about 2.5 and about 3.5. In certain embodiments, such isocyanates
have a functionality between about 2.6 and about 3.1. In certain
embodiments, such isocyanates have a functionality of about 3.
[0546] In certain embodiments, an isocyanate reagent is selected
from the group consisting of: 1,6-hexamethylaminediisocyanate
(HDI), isophorone diisocyanate (IPDI), 4,4'
methylene-bis(cyclohexyl isocyanate) (H.sub.12MDI), 2,4-toluene
diisocyanate (TDI), 2,6-toluene diisocyanate (TDI),
diphenylmethane-4,4'-diisocyanate (MDI),
diphenylmethane-2,4'-diisocyanate (MDI), xylylene diisocyanate
(XDI), 1,3-Bis(isocyanatomethyl)cyclohexane (H6-XDI),
2,2,4-trimethylhexamethylene diisocyanate,
2,4,4-trimethylhexamethylene diisocyanate (TMDI),
m-tetramethylxylylene diisocyanate (TMXDI), p-tetramethylxylylene
diisocyanate (TMXDI), isocyanatomethyl-1,8-ictane diisocyanate
(TIN), triphenylmethane-4,4',4''triisocyanate,
Tris(p-isocyanatomethyl)thiosulfate,
1,3-Bis(isocyanatomethyl)benzene, 1,4-tetramethylene diisocyanate,
trimethylhexane diisocyanate, 1,6-hexamethylene diisocyanate,
1,4-cyclohexyl diisocyanate, lysine diisocyanate, and mixtures of
any two or more of these.
[0547] Isocyanates suitable for certain embodiments of the present
invention are available commercially under various trade names.
Examples of suitable commercially available isocyanates include
materials sold under trade names: Desmodur.RTM. (Bayer Material
Science), Tolonate.RTM. (Perstorp), Takenate.RTM. (Takeda),
Vestanat.RTM. (Evonik), Desmotherm.RTM. (Bayer Material Science),
Bayhydur.RTM. (Bayer Material Science), Mondur (Bayer Material
Science), Suprasec (Huntsman Inc.), Lupranate.RTM. (BASF), Trixene
(Baxenden), Hartben.RTM. (Benasedo), Ucopol.RTM. (Sapici), and
Basonat.RTM. (BASF). Each of these trade names encompasses a
variety of isocyanate materials available in various grades and
formulations. The selection of suitable commercially-available
isocyanate materials as reagents to produce polyurethane
compositions for a particular application is within the capability
of one skilled in the art of polyurethane technology using the
teachings and disclosure of this patent application along with the
information provided in the product data sheets supplied by the
above-mentioned suppliers.
[0548] Additional isocyanates suitable for certain embodiments of
the present invention are sold under the trade name Lupranate.RTM.
(BASF). In certain embodiments, the isocyanates are selected from
the group consisting of the materials shown in Table 1:
TABLE-US-00019 TABLE 1 Nominal Products Description % NCO Funct.
Lupranate M 4,4' MDI 33.5 2 Lupranate MS 4,4' MDI 33.5 2 Lupranate
MI 2,4' and 4,4' MDI Blend 33.5 2 Lupranate LP30 Liquid Pure 4,4'
MDI 33.1 2 Lupranate 227 Monomeric/Modified MDI Blend 32.1 2
Carbodiimide Modified MDI Lupranate 5143 Carbodiimide Modified 4,4'
MDI 29.2 2.2 Lupranate MM103 Carbodiimide Modified 4,4' MDI 29.5
2.2 Lupranate 219 Carbodiimide Modified 4,4' MDI 29.2 2.2 Lupranate
81 Carbodiimide Modified MDI 29.5 2.2 Lupranate 218 Carbodiimide
Modified MDI 29.5 2.2 Polymeric MDI (PMDI) Lupranate M10 Low Funct.
Polymeric 31.7 2.2 Lupranate R2500U Polymeric MDI Variant 31.5 2.7
Lupranate M20S Mid-Functionality Polymeric 31.5 2.7 Lupranate M20FB
Mid-Functionality Polymeric 31.5 2.7 Lupranate M70L
High-Functionality Polymeric 31 3 Lupranate M200 High-Functionality
Polymeric 30 3.1 Polymeric MDI Blends and Derivatives Lupranate 241
Low Functionality Polymeric 32.6 2.3 Lupranate 230 Low Viscosity
Polymeric 32.5 2.3 Lupranate 245 Low Viscosity Polymeric 32.3 2.3
Lupranate TF2115 Mid Functionality Polymeric 32.3 2.4 Lupranate 78
Mid Functionality Polymeric 32 2.3 Lupranate 234 Low Functionality
Polymeric 32 2.4 Lupranate 273 Low Viscosity Polymeric 32 2.5
Lupranate 266 Low Viscosity Polymeric 32 2.5 Lupranate 261 Low
Viscosity Polymeric 32 2.5 Lupranate 255 Low Viscosity Polymeric
31.9 2.5 Lupranate 268 Low Viscosity Polymeric 30.6 2.4 Select MDI
Prepolymers Lupranate 5010 Higher Functional Prepolymer 28.6 2.3
Lupranate 223 Low Visc. Derivative of Pure MDI 27.5 2.2 Lupranate
5040 Mid Functional, Low Viscosity 26.3 2.1 Lupranate 5110
Polymeric MDI Prepolymer 25.4 2.3 Lupranate MP102 4,4' MDI
Prepolymer 23 2 Lupranate 5090 Special 4,4' MDI Prepolymer 23 2.1
Lupranate 5050 Mid Functional, Mid NCO Prepol 21.5 2.1 Lupranate
5030 Special MDI Prepolymer 18.9 NA Lupranate 5080 2,4'-MDI
Enhanced Prepolymer 15.9 2 Lupranate 5060 Low Funct, Higher MW
Prepol 15.5 2 Lupranate 279 Low Funct, Special Prepolymer 14 2
Lupranate 5070 Special MDI Prepolymer 13 2 Lupranate 5020 Low
Functionality, Low NCO 9.5 2 Toluene Diisocyanate (TDI) Lupranate
T80- 80/20: 2,4/2,6 TDI 48.3 2 Lupranate T80- High Acidity TDI 48.3
2 Lupranate 8020 80/20: TDI/Polymeric MDI 44.6 2.1
[0549] Other isocyanates suitable for certain embodiments of the
present invention are sold under the trade name Desmodur.RTM.
available from Bayer Material Science. In certain embodiments, the
isocyanates are selected from the group consisting of the materials
shown in Table 2:
TABLE-US-00020 TABLE 2 Trade Name Description Desmodur .RTM. 2460 M
Monomeric diphenylmethane diisocyanate with high 2,4'-isomer
content Desmodur .RTM. 44 M A monomeric
diphenylmethanc-4,4'-diisocyanate (MDI). Desmodur .RTM. 44 MC
Desmodur 44 MC Flakes is a monomeric diphenylmethane-4,4'-
diisocyanate (MDI). Desmodur .RTM. BL 1100/1 Blocked aromatic
polyisocyanate based on TDI Desmodur .RTM. BL 1265 Blocked aromatic
polyisocyanate based on TDI MPA/X Desmodur .RTM. BL 3175 SN
Blocked, aliphatic polyisocyanate based on HDI Desmodur .RTM. BL
3272 MPA Blocked aliphatic polyisocyanate based on HDI Desmodur
.RTM. BL 3370 MPA Blocked aliphatic polyisocyanate based on HDI
Desmodur .RTM. BL 3475 Aliphatic crosslinking stoving urethane
resin based on HDI/IPDI BA/SN Desmodur .RTM. BL 3575/1 Blocked
aliphatic polyisocyanate based on HDI MPA/SN Desmodur .RTM. BL 4265
SN Blocked, aliphatic polyisocyanate based on IPDI Desmodur .RTM.
BL 5375 Blocked aliphatic polyisocyanate based on H 12 MDI Desmodur
.RTM. CD-L Desmodur CD-L is a modified isocyanate based on
diphenylmethane-4,4'-diisocyanate. Desmodur .RTM. CD-S Desmodur
CD-S is a modified isocyanate based on
diphenylmethane-4,4'-diisocyanate. Desmodur .RTM. D XP 2725
Hydrophilically modified polyisocyanate Desmodur .RTM. DA-L
Hydrophilic aliphatic polyisocyanate based on hexamethylene
diisocyanate Desmodur .RTM. DN Aliphatic polyisocyanate of low
volatility Desmodur .RTM. E 1160 Aromatic polyisocyanate prepolymer
based on toluene diisocyanate Desmodur .RTM. E 1361 BA Aromatic
polyisocyanate prepolymer based on toluylene diisocyanate Desmodur
.RTM. E 1361 Aromatic polyisocyanate prepolymer based on toluene
diisocyanate MPA/X Desmodur .RTM. E 14 Aromatic polyisocyanate
prepolymer based on toluene diisocyanate Desmodur .RTM. E 15
Aromatic polyisocyanate prepolymer based on toluene diisocyanate.
Desmodur .RTM. E 1660 Aromatic polyisocyanate prepolymer based on
toluene diisocyanate. Desmodur .RTM. E 1750 PR Polyisocyanate
prepolymer based on toluene diisocyanate Desmodur .RTM. E 20100
Modified polyisocyanate prepolymer based on diphenylmethane
diisocyanate. Desmodur .RTM. E 21 Aromatic polyisocyanate
prcpolymer based on diphenylmethane diisocyanate (MDI). Desmodur
.RTM. E 2190 X Aromatic polyisocyanate prepolymer based on
diphenylmethane diisocyanate (MDI) Desmodur .RTM. E 22 Aromatic
polyisocyanate prepolymer based on diphenylmethane diisocyanate.
Desmodur .RTM. E 2200/76 Desmodur E 2200/76 is a prepolymer based
on (MDI) with isomers. Desmodur .RTM. E 23 Aromatic polyisocyanate
prepolymer based on diphenylmethane diisocyanate (MDI). Desmodur
.RTM. E 29 Polyisocyanate prepolymer based on diphenylmethane
diisocyanate. Desmodur .RTM. E 305 Desmodur E 305 is a largely
linear aliphatic NCO prepolymer based on hexamethylene
diisocyanate. Desmodur .RTM. E 3265 Aliphatic polyisocyanate
prepolymer based on hexamethylene MPA/SN diisocyanate (HDI)
Desmodur .RTM. E 3370 Aliphatic polyisocyanate prepolymer based on
hexamethylene diisocyanate Desmodur .RTM. E XP 2605 Polyisocyanate
prepolymer based on toluene diisocyanate and diphenylmethan
diisocyanate Desmodur .RTM. E XP 2605 Polyisocyanate prepolymer
based on toluene diisocyanate and diphenylmethan diisocyanate
Desmodur .RTM. E XP 2715 Aromatic polyisocyanate prepolymer based
on 2,4'-diphenylmethane diisocyanate (2,4'-MDI) and a hexanediol
adipate Desmodur .RTM. E XP 2723 Aromatic polyisocyanate prepolymer
based on diphenylmethane diisocyanate (MDI). Desmodur .RTM. E XP
2726 Aromatic polyisocyanate prepolymer based on
2,4'-diphenylmethane diisocyanate (2,4'-MDI) Desmodur .RTM. E XP
2727 Aromatic polyisocyanate prepolymer based on diphenylmethane
diisocyanate. Desmodur .RTM. E XP 2762 Aromatic polyisocyanate
prepolymer based on diphenylmethane diisocyanate (MDI). Desmodur
.RTM. H Monomeric aliphatic diisocyanate Desmodur .RTM. HL
Aromatic/aliphatic polyisocyanate based on toluylene diisocyanate/
hexamethylene diisocyanate Desmodur .RTM. I Monomeric
cycloaliphatic diisocyanate. Desmodur .RTM. IL 1351 Aromatic
polyisocyanate based on toluene diisocyanate Desmodur .RTM. IL 1451
Aromatic polyisocyanate based on toluene diisocyanate Desmodur
.RTM. IL BA Aromatic polyisocyanate based on toluene diisocyanate
Desmodur .RTM. IL EA Aromatic polyisocyante resin based on
toluylene diisocyanate Desmodur .RTM. L 1470 Aromatic
polyisocyanate based on toluene diisocyanate Desmodur .RTM. L 67 BA
Aromatic polyisocyanate based on tolulene diisocyanate Desmodur
.RTM. L 67 MPA/X Aromatic polyisocyanate based on tolulene
diisocyanate Desmodur .RTM. L 75 Aromatic polyisocyanate based on
tolulene diisocyanate Desmodur .RTM. LD Low-functionality
isocyanate based on hexamethylene diisocyanate (HDI) Desmodur .RTM.
LS 2424 Monomeric diphenylmethane diisocyanate with high
2,4'-isomer content Desmodur .RTM. MT Polyisocyanate prepolymer
based on diphenylmethane diisocyanate Desmodur .RTM. N 100
Aliphatic polyisocyanate (HDI biuret) Desmodur .RTM. N 3200
Aliphatic polyisocyanate (low-viscosity HDI biuret) Desmodur .RTM.
N 3300 Aliphatic polyisocyanate (HDI trimer) Desmodur .RTM. N 3368
BA/SN Aliphatic polyisocyanate (HDI trimer) Desmodur .RTM. N 3368
SN Aliphatic polyisocyanate (HDI trimer) Desmodur .RTM. N 3386
BA/SN Aliphatic polyisocyanate (HDI trimer) Desmodur .RTM. N 3390
BA Aliphatic polyisocyanate (HDI trimer) Desmodur .RTM. N 3390
BA/SN Aliphatic polyisocyanate (HDI trimer) Desmodur .RTM. N 3400
Aliphatic polyisocyanate (HDI uretdione) Desmodur .RTM. N 3600
Aliphatic polyisocyanate (low-viscosity HDI trimer) Desmodur .RTM.
N 3790 BA Aliphatic polyisocyanate (high functional HDI trimer)
Desmodur .RTM. N 3800 Aliphatic polyisocyanate (flexibilizing HDI
trimer) Desmodur .RTM. N 3900 Low-viscosity, aliphatic
polyisocyanate resin based on hexamethylene diisocyanate Desmodur
.RTM. N 50 BA/MPA Aliphatic polyisocyanate (HDI biuret) Desmodur
.RTM. N 75 BA Aliphatic polyisocyanate (HDI biuret) Desmodur .RTM.
N 75 MPA Aliphatic polyisocyanate (HDI biuret) Desmodur .RTM. N 75
MPA/X Aliphatic polyisocyanate (HDI biuret) Desmodur .RTM. NZ 1
Aliphatic polyisocyanate Desmodur .RTM. PC-N Desmodur PC-N is a
modified diphenyl-methane-4,4'-diisocyanate (MDI). Desmodur .RTM.
PF Desmodur PF is a modified diphenyl-methane-4,4'-diisocyanate
(MDI). Desmodur .RTM. PL 340, 60% Blocked aliphatic polyisocyanate
based on IPDI BA/SN Desmodur .RTM. PL 350 Blocked aliphatic
polyisocyanate based on HDI Desmodur .RTM. RC Solution of a
polyisocyanurate of toluene diisocyanate (TDI) in ethyl acetate.
Desmodur .RTM. RE Solution of
triphenylmethane-4,4',4''-triisocyanate in ethyl acetate Desmodur
.RTM. RFE Solution of tris(p-isocyanatophenyl) thiophosphate in
ethyl acetate Desmodur .RTM. RN Solution of a polyisocyanurate with
aliphatic and aromatic NCO groups in ethyl acetate. Desmodur .RTM.
T 100 Pure 2,4'-toluene diisocyanate (TDI) Desmodur .RTM. T 65 N
2,4- and 2,6-toluene diisocyanate (TDI) in the ratio 67:33 Desmodur
.RTM. T 80 2,4- and 2,6-toluene diisocyanate (TDI) in the ratio
80:20 Desmodur .RTM. T 80 P 2,4- and 2,6-toluene diisocyanate (TDI)
in the ratio 80:20 with an increased content of hydrolysable
chlorine Desmodur .RTM. VH 20 N Polyisocyanate based on
diphenylmethane diisocyanate Desmodur .RTM. VK Desmodur VK products
re mixtures of diphenylmethane-4,4'- diisocyanate (MDI) with
isomers and higher functional homologues Desmodur .RTM. VKP 79
Desmodur VKP 79 is a modified diphenylmethane-4,4'-diisocyanate
(MDI) with isomers and homologues. Desmodur .RTM. VKS 10 Desmodur
VKS 10 is a mixture of diphenylmethane-4,4'- diisocyanate (MDI)
with isomers and higher functional homologues (PMDI). Desmodur
.RTM. VKS 20 Desmodur VKS 20 is a mixture of diphenylmethane-4,4'-
diisocyanate (MDI) with isomers and higher functional homologues
(PMDI). Desmodur .RTM. VKS 20 F Desmodur VKS 20 F is a mixture of
diphenylmethane-4,4'- diisocyanate (MDI) with isomers and higher
functional homologues Desmodur .RTM. VKS 70 Desmodur VKS 70 is a
mixture of diphenylmethane-4,4'- diisocyanate (MDI) with isomers
and homologues. Desmodur .RTM. VL Aromatic polyisocyanate based on
diphenylmethane diisocyanate Desmodur .RTM. VP LS 2078/2 Blocked
aliphatic polyisocyanate based on IPDI Desmodur .RTM. VP LS 2086
Aromatic polyisocyanate prepolymer based on diphenylmethane
diisocyanate Desmodur .RTM. VP LS 2257 Blocked aliphatic
polyisocyanate based on HDI Desmodur .RTM. VP LS 2371 Aliphatic
polyisocyanate prepolymer based on isophorone diisocyanate.
Desmodur .RTM. VP LS 2397 Desmodur VP LS 2397 is a linear
prepolymer based on polypropylene ether glycol and diphenylmethane
diisocyanate (MDI). It contains Desmodur .RTM. W Monomeric
cycloaliphatic diisocyanate Desmodur .RTM. W/1 Monomeric
cycloaliphatic diisocyanate Desmodur .RTM. XP 2404 Desmodur XP 2404
is a mixture of monomeric polyisocyanates Desmodur .RTM. XP 2406
Aliphatic polyisocyanate prepolymer based on isophorone
diisocyanate Desmodur .RTM. XP 2489 Aliphatic polyisocyanate
Desmodur .RTM. XP 2505 Desmodur XP 2505 is a prepolymer containing
ether groups based on diphenylmethane-4,4'-diisocyanates (MDI) with
isomers and higher Desmodur .RTM. XP 2551 Aromatic polyisocyanate
based on diphenylmethane diisocyanate Desmodur .RTM. XP 2565
Low-viscosity, aliphatic polyisocyanate resin based on isophorone
diisocyanate. Desmodur .RTM. XP 2580 Aliphatic polyisocyanate based
on hexamethylene diisocyanate Desmodur .RTM. XP 2599 Aliphatic
prepolymer containing ether groups and based on
hexamethylene-1,6-diisocyanate (HDI) Desmodur .RTM. XP 2617
Desmodur XP 2617 is a largely linear NCO prepolymer based on
hexamethylene diisocyanate. Desmodur .RTM. XP 2665 Aromatic
polyisocyanate prepolymer based on diphenylmethane diisocyanate
(MDI). Desmodur .RTM. XP 2675 Aliphatic polyisocyanate (highly
functional HDI trimer) Desmodur .RTM. XP 2679 Aliphatic
polyisocyanate (HDI allophanate trimer) Desmodur .RTM. XP 2714
Silane-functional aliphatic polyisocyanate based on hexamethylene
diisocyanate Desmodur .RTM. XP 2730 Low-viscosity, aliphatic
polyisocyanate (HDI uretdione)
Desmodur .RTM. XP 2731 Aliphatic polyisocyanate (HDI allophanate
trimer) Desmodur .RTM. XP 2742 Modified aliphatic Polyisocyanate
(HDI-Trimer), contains SiO2- nanoparticles
[0550] Additional isocyanates suitable for certain embodiments of
the present invention are sold under the trade name Tolonate.RTM.
(Perstorp). In certain embodiments, the isocyanates are selected
from the group consisting of the materials shown in Table 3:
TABLE-US-00021 TABLE 3 Tolonate .TM. D2 a blocked aliphatic
polyisocyanate, supplied at 75% solids in aromatic solvent Tolonate
.TM. HDB a viscous solvent-free aliphatic polyisocyanate Tolonate
.TM. HDB-LV a solvent free low viscosity aliphatic polyisocyanate
Tolonate .TM. HDB 75 B an aliphatic polyisocyanate, supplied at 75%
solids in methoxy propyl acetate Tolonate .TM. HDB 75 BX an
aliphatic polyisocyanate, supplied at 75% solids Tolonate .TM. HDT
a medium viscosity, solvent-free aliphatic polyisocyanate Tolonate
.TM. HDT-LV is a solvent free low viscosity aliphatic
polyisocyanate Tolonate .TM. HDT-LV2 a solvent free, very low
viscosity aliphatic polyisocyanate Tolonate .TM. HDT 90 an
aliphatic polyisocyanate, based on HDI-trimer (isocyanurate),
supplied at 90% solids Tolonate .TM. HDT 90 B an aliphatic
polyisocyanate, based on HDT-trimer (isocyanurate), supplied at 90%
solids Tolonate .TM. IDT 70 B an aliphatic polyisocyanate, based on
HDT-trimer (isocyanurate), supplied at 70% solids Tolonate .TM. IDT
70 S an aliphatic polyisocyanate, based on HDI-trimer
(isocyanurate), supplied at 70% solids Tolonate .TM. X FD 90 B a
high functionality, fast drying aliphatic polyisocyanate based on
HDT-trimer, supplied at 90% solids
[0551] Other isocyanates suitable for certain embodiments of the
present invention are sold under the trade name Mondur.RTM.
available from Bayer Material Science. In certain embodiments, the
isocyanates are selected from the group consisting of the materials
shown in Table 4:
TABLE-US-00022 TABLE 4 Trade Name Description MONDUR 445 TDI/MDI
blend polyisocyanate; blend of toluene diisocyanate and polymeric
diphenylmethane diisocyanate; NCO weight 44.5-45.2% MONDUR 448
modified polymeric diphenylmethane diisocyanate (pMDI) prepolymer;
NCO weight 27.7%; viscosity 140 mPa s @ 25.degree. C.; equivalent
weight 152; functionality 2.2 MONDUR 489 modified polymeric
diphenylmethane diisocyanate (pMDI); NCO weight 31.5%; viscosity
700 mPa s @ 25.degree. C.; equivalent weight 133; functionality 3.0
MONDUR 501 modified monomeric diphenylmethane diisocyanate (mMDI);
isocyanate- terminated polyester prepolymer; NCO weight 19.0%;
viscosity 1,100 mPa s @ 25.degree. C.; equivalent weight 221;
functionality 2 MONDUR 541 polymeric diphenylmethane diisocyanate
(pMDI); binder for composite wood products and as a raw material in
adhesive formulations; NCO weight 31.5%; viscosity 200 mPa s @
25.degree. C. MONDUR 582 polymeric diphenylmethane diisocyanate
(pMDI); binder for composite wood products and as a raw material in
adhesive formulations; NCO weight 31.0%; viscosity 200 mPa s @
25.degree. C. MONDUR 541-Light polymeric diphenylmethane
diisocyanate (pMDI); NCO weight 32.0%; viscosity 70 mPa s @
25.degree. C.; equivalent weight 131; functionality 2.5 MONDUR 841
modified polymeric MDI prepolymer; NCO, Wt 30.5%; Acidity, Wt
0.02%; Amine Equivalent 132; Viscosity at 25.degree. C., mPa s 350;
Specific gravity at 25.degree. C. 1.24; Flash Point, PMCC, .degree.
F. > 200 MONDUR 1437 modified diphenylmethane diisocyanate
(mMDI); isocyanate-terminated polyether prepolymer; NCO weight
10.0%; viscosity 2,500 mPa s @ 25.degree. C.; equivalent weight
420; functionality 2 MONDUR 1453 modified diphenylmethane
diisocyanate (mMDI); isocyanate-terminated polyether prepolymer
based on polypropylene ether glycol (PPG); NCO weight 16.5%;
viscosity 600 mPa s @ 25.degree. C.; equivalent weight 254;
functionality 2 MONDUR 1515 modified polymeric diphenylmethane
diisocyanate (pMDI) prepolymer; used in the production of rigid
polyurethane foams, especially for the appliance industry; NCO
weight 30.5%; viscosity 350 mPa s @ 25.degree. C. MONDUR 1522
modified monomeric 4,4-diphenylmethane diisocyanate (mMDI); NCO
weight 29.5%; viscosity 50 mPa s @ 25.degree. C.; equivalent weight
143; functionality 2.2 MONDUR MA-2300 modified monomeric MDI,
allophanate-modified 4,4'-diphenylmethane diisocyanate (mMDI); NCO
weight 23.0%; viscosity 450 mPa s @ 25.degree. C.; equivalent
weight 183; functionality 2.0 MONDUR MA 2600 modified monomeric
MDI, allophanate-modified 4,4'-diphenylmethane diisocyanate (mMDI);
NCO weight 26.0%; viscosity 100 mPa s @ 25.degree. C.; equivalent
weight 162; functionality 2.0 MONDUR MA 2601 aromatic diisocyanate
blend, allophanate-modified 4,4'-diphenylmethane diisocyanate (MDI)
blended with polymeric diphenylmethane diisocyanate (pMDI)
containing 2,4'-isomer; NCO weight 29.0%; viscosity 60 mPa s @
25.degree. C.; equivalent weight 145; functionality 2.2 MONDUR MA
2603 MDI prepolymer; isocyanate-terminated (MDI) prepolymer blended
with an allophanate-modified 4,4'-diphenylmethane diisocyanate
(MDI); NCO weight 16.0%; viscosity 1,050 mPa s @ 25.degree. C.;
equivalent weight 263; functionality 2.0 MONDUR MA-2902 modified
monomeric MDI, allophanate-modified 4,4'-diphenylmethane
diisocyanate (mMDI); NCO weight 29.0%; viscosity 40 mPa s @
25.degree. C.; equivalent weight 145; functionality 2.0 MONDUR
MA-2903 modified monomeric MDI; isocyanate-terminated (MDI)
prepolymer; NCO weight 19.0%; viscosity 400 mPa s @ 25.degree. C.;
equivalent weight 221; functionality 2.0 MONDUR MA-2904
Allophanate-modified MDI polyether prepolymer; NCO weight 12.0%;
viscosity 1,800 mPa s @ 25.degree. C.; equivalent weight 350;
functionality of 2.0 MONDUR MB high-purity grade difunctional
isocyanante, diphenylmethane 4,4'-diiscocyanate; used in production
of polyurethane elastomers, adhesives, coatings and intermediate
polyurethane products; appearance colorless solid or liquid;
specific gravity @ 50.degree. C. .+-. 15.5 1.19; flash point
202.degree. C. PMCC; viscosity (in molten form) 4.1 mPa s; bult
density 10 lb/gal (fused) or 9.93 lb/gal (molten); freezing
temperature 39.degree. C. MONDUR MLQ monomeric diphenylmethan
diisocyanate; used in a foams, cast elastomers, coatings and
adhesives; appearance light yellow clear liquid, NCO 33.4% wt; 1.19
specific gravity at 25.degree. C., 196.degree. C. flash point, DIN
51758; 11-15.degree. C. freezing temperature MONDUR MQ
high-purity-grade difunctional isocyanate, diphenylmethane
4,4'-diisocyanate (MDI); used in production of solid polyurethane
elastomers, adhesives, coatings and in intermediate polyurethane
products; appearance colorless solid or liquid; specific gravity
1.19 @ 50.degree. C.; flash point 202.degree. C. PMCC; viscosity
4.1 mPa s; bulk density 10 lb./gal (fused) or 9.93 lb./gal
(molten); freezing temperature 39.degree. C. MONDUR MR polymeric
diphenylmethane diisocyanate (pMDI); NCO weight 31.5%; viscosity
200 mPa s @ 25.degree. C.; equivalent weight 133; functionality 2.8
MONDUR MR polymeric diphenylmethane diisocyanate (pMDI); NCO weight
31.5%; viscosity LIGHT 200 mPa s @ 25.degree. C.; equivalent weight
133; functionality 2.8 MONDUR MR-5 polymeric diphenylmethane
diisocyanate (pMDI); NCO weight 32.5%; viscosity 50 mPa s @
25.degree. C.; equivalent weight 129; functionality 2.4 MONDUR MRS
2,4' rich polymeric diphenylmethane diisocyanate (pMDI); NCO weight
31.5%; viscosity 200 mPa s @ 25.degree. C.; equivalent weight 133;
functionality 2.6 MONDUR MRS 2 2,4' rich polymeric diphenylmethane
diisocyanate (pMDI); NCO weight 33.0%; viscosity 25 mPa s @
25.degree. C.; equivalent weight 127; functionality 2.2 MONDUR
MRS-4 2,4' rich polymeric diphenylmethane diisocyanate (pMDI); NCO
weight 32.5%; viscosity 40 mPa s @ 25.degree. C.; equivalent weight
129; functionality 2.4 MONDUR MRS-5 2,4' rich polymeric
diphenylmethane diisocyanate (pMDI); NCO weight 32.3%; viscosity 55
mPa s @ 25.degree. C.; equivalent weight 130; functionality 2.4
MONDUR PC modified 4,4' diphenylmethane diisocyanate (mMDI); NCO
weight 25.8%; viscosity 145 mPa s @ 25.degree. C.; equivalent
weight 163; functionality 2.1 MONDUR PF modified 4,4'
diphenylmethane diisocyanate (mMDI) prepolymer; NCO weight 22.9%;
viscosity 650 mPa s @ 25.degree. C.; equivalent weight 183;
functionality 2 MONDUR TD-65 monomeric toluene diisocyanate (TDI);
65/35 mixture of 2,4 and 2.6 TDI; NCO weight 48%; viscosity 3 mPa s
@ 25.degree. C.; equivalent weight 87.5; functionality 2 MONDUR
TD-80 monomeric toluene diisocyanate (TDI); 80/20 mixture of the
2,4 and 2,6 isomer; GRADE A NCO weight 48%; viscosity 5 mPa s @
25.degree. C.; equivalent weight 87.5; functionality 2 MONDUR TD-80
monomeric toluene diisocyanate (TDI); 80/20 mixture of the 2,4 and
2,6 isomer; GRADE A/GRADE B NCO weight 48%; viscosity 5 mPa s @
25.degree. C.; equivalent weight 87.5; functionality 2
Appendix C Additives
[0552] As described above, in some embodiments, methods and
compositions of the present invention comprise so-called B-side
mixtures comprising one or more of the aliphatic polycarbonate
polyols. To produce a foam, the B-side mixture is reacted with an
A-side mixture containing one or more polyisocyanates (or
polyisocyanate precursors). Typically, one or both of the A-side
and B-side mixtures will contain additional components and
additives of various sorts. In certain embodiments, the B-side
mixtures from which any of the foams of the present invention are
produced contain one or more additional polyols and/or one or more
additives. In certain embodiments, the additives are selected from
the group consisting of: solvents, water, catalysts, surfactants,
blowing agents, colorants, UV stabilizers, flame retardants,
antimicrobials, plasticizers, cell-openers, antistatic
compositions, compatibilizers, and the like. In certain
embodiments, the B-side mixtures comprise additional reactive small
molecules such as amines, water, alcohols, thiols or carboxylic
acids that participate in bond-forming reactions with
isocyanates.
A. Additional Polyols
[0553] In certain embodiments, the B-side mixtures of the present
invention comprise aliphatic polycarbonate polyols as described
above in combination with one or more additional polyols such as
are traditionally used in polyurethane foam compositions. In
embodiments where additional polyols are present, they may comprise
up to about 95 weight percent of the total polyol content with the
balance of the polyol mixture made up of one or more aliphatic
polycarbonate polyols described in Section I above and in the
examples and specific embodiments herein.
[0554] In embodiments where B-side mixtures of the present
invention comprise or derived from a mixture of one or more
aliphatic polycarbonate polyols and one or more additional polyols,
the additional polyols are selected from the group consisting of
polyether polyols, polyester polyols, polystyrene polyols,
polyether-carbonate polyols, polyether-ester carbonates, and
mixtures of any two or more of these. In certain embodiments,
B-side mixtures of the present invention comprise or derived from a
mixture of one or more aliphatic polycarbonate polyols as described
herein and one or more other polyols selected from the group
consisting of materials available commercially under the trade
names: Voranol.RTM. (Dow), SpecFlex.RTM. (Dow), Tercarol.RTM.
(Dow), Caradol.RTM. (Shell), Hyperliter), Acclaim.RTM. (Bayer
Material Science), Ultracel.RTM. (Bayer Material Science),
Desmophen.RTM. (Bayer Material Science), and Arcol.RTM. (Bayer
Material Science).
[0555] In certain embodiments, B-side mixtures of the present
invention comprise mixtures containing polyether polyols in
combination with one or more aliphatic polycarbonate polyols as
described herein. In certain embodiments, such polyether polyols
are characterized in that they have an Mn between about 500 and
about 10,000 g/mol. In certain embodiments, such polyether polyols
have an Mn between about 500 and about 5,000 g/mol. In certain
embodiments, the polyether polyols comprise polyethylene glycol. In
certain embodiments, the polyether polyols comprise polypropylene
glycol.
[0556] Polyether polyols that may be present include those which
can be obtained by known methods, for example, polyether polyols
can be produced by anionic polymerization with alkali hydroxides
such as sodium hydroxide or potassium hydroxide or alkali
alcoholates, such as sodium methylate, sodium ethylate, potassium
ethylate or potassium isopropylate as catalysts and with the
addition of at least one initiator molecule containing 2 to 8,
preferably 3 to 8, reactive hydrogens or by cationic polymerization
with Lewis acids such as antimony pentachloride, boron trifluoride
etherate, etc., or bleaching earth as catalysts from one or more
alkylene oxides with 2 to 4 carbons in the alkylene radical. Any
suitable alkylene oxide may be used such as 1,3-propylene oxide,
1,2- and 2,3 butylene oxide, amylene oxides, styrene oxide, and
preferably ethylene oxide and propylene oxide and mixtures of these
oxides. The polyalkylene polyether polyols may be prepared from
other starting materials such as tetrahydrofuran and alkylene
oxide-tetrahydrofuran mixtures; epihalohydrins such as
epichlorohydrin; as well as aralkylene oxides such as styrene
oxide. The polyalkylene polyether polyols may have either primary
or secondary hydroxyl groups, preferably secondary hydroxyl groups
from the addition of propylene oxide onto an initiator because
these groups are slower to react. Included among the polyether
polyols are polyoxyethylene glycol, polyoxypropylene glycol,
polyoxybutylene glycol, polytetramethylene glycol, block
copolymers, for example, combinations of polyoxypropylene and
polyoxyethylene glycols, poly-1,2-oxybutylene and polyoxyethylene
glycols, poly-1,4-tetramefhylene and polyoxyethylene glycols, and
copolymer glycols prepared from blends or sequential addition of
two or more alkylene oxides. The polyalkylene polyether polyols may
be prepared by any known process such as, for example, the process
disclosed by Wurtz in Encyclopedia of Chemical Technology, Vol. 7,
pp. 257-262, published by Interscience Publishers, Inc. (1951) or
in U.S. Pat. No. 1,922,459. Polyethers include the alkylene oxide
addition products of polyhydric alcohols such as ethylene glycol,
propylene glycol, dipropylene glycol, trimethylene glycol,
1,2-butanediol, 1,5-pentanediol, 1,6hexanediol, 1,7-heptanediol,
hydroquinone, resorcinol glycerol, glycerine,
1,1,1-trimethylol-propane, 1,1,1trimethylolethane, pentaerythritol,
1,2,6-hexanetriol, a-methyl glucoside, sucrose, and sorbitol. Also
included within the term "polyhydric alcohol" are compounds derived
from phenol such as 2,2-bis(4-hydroxyphenyl)-propane, commonly
known as Bisphenol A. Particularly preferred in the polyol
composition is at least one polyol which is initiated with a
compound having at least two primary or secondary amine groups, a
polyhydric alcohol having 4 or more hydroxyl groups, such as
sucrose, or a mixture of initiators employing a polyhydric alcohol
having at least 4 hydroxyl groups and compounds having at least two
primary or secondary amine groups. Suitable organic amine
initiators which may be condensed with alkylene oxides include
aromatic amines-such as aniline, N-alkylphenylene-diamines, 2,4'-,
2,2'-, and 4,4'-methylenedianiline, 2,6- or 2,4-toluenediamine,
vicinal toluenediamines, o-chloroaniline, p-aminoaniline,
1,5-diaminonaphthalene, methylene dianiline, the various
condensation products of aniline and formaldehyde, and the isomeric
diaminotoluenes; and aliphatic amines such as mono-, di-, and
trialkanolamines, ethylene diamine, propylene diamine,
diethylenetriamine, methylamine, triisopropanolamine,
1,3-diaminopropane, 1,3-diaminobutane, and 1,4-diaminobutane.
Preferable amines include monoethanolamine, vicinal
toluenediamines, ethylenediamines, and propylenediamine. Yet
another class of aromatic polyether polyols contemplated for use in
this invention are the Mannich-based polyol an alkylene oxide
adduct of phenol/formaldehyde/alkanolamine resin, frequently called
a "Mannich" polyol such as disclosed in U.S. Pat. Nos. 4,883,826;
4,939,182; and 5,120, 815.
[0557] In certain embodiments where additional polyols are present,
they comprise from about 5 weight percent to about 95 weight
percent of the total polyol content with the balance of the polyol
mixture made up of one or more aliphatic polycarbonate polyols
described in Section I above and in the examples and specific
embodiments herein. In certain embodiments, up to about 75 weight
percent of the total polyol content of the B-side mixture is
aliphatic polycarbonate polyol. In certain embodiments, up to about
50 weight percent of the total polyol content of the B-side mixture
is aliphatic polycarbonate polyol. In certain embodiments, up to
about 40 weight percent, up to about 30 weight percent, up to about
25 weight percent, up to about 20 weight percent, up to about 15
weight percent, or up to about 10 weight percent of the total
polyol content of the B-side mixture is aliphatic polycarbonate
polyol. In certain embodiments, at least about 5 weight percent of
the total polyol content of the B-side mixture is aliphatic
polycarbonate polyol. In certain embodiments, at least about 10
weight percent of the total polyol content of the B-side mixture is
aliphatic polycarbonate polyol. In certain embodiments, at least
about 15 weight percent, at least about 20 weight percent, at least
about 25 weight percent, at least about 40 weight percent, or at
least about 50 weight percent, of the total polyol content of the
B-side mixture is aliphatic polycarbonate polyol.
B. Catalysts
[0558] In certain embodiments, B-side mixtures contain one or more
catalysts for the reaction of the polyol (and water, if present)
with the polyisocyanate. Any suitable urethane catalyst may be
used, including tertiary amine compounds and organometallic
compounds. Exemplary tertiary amine compounds include
triethylenediamine, N-methylmorpholine,
N,N-dimethylcyclohexylamine, pentamethyldiethylenetriamine,
tetramethylethylenediamine,
1-methyl-4-dimethylaminoethylpiperazine,
3-methoxy-N-dimethylpropylamine, N-ethylmorpholine,
diethylethanolamine, N-cocomorpholine, N,N-dimethyl-N',N'-dimethyl
isopropylpropylenediamine, N,N-diethyl-3-diethylaminopropylamine
dimethylbenzylamine, 1,8-Diazabicycloundec-7-ene (DBU),
1,4-diazabicyclo[2.2.2]octane (DABCO) triazabicyclodecene (TBD),
and N-methyltriazabicyclodecene. (MTBD) Exemplary organometallic
catalysts include organomercury, organolead, organoferric and
organotin catalysts, with organotin catalysts being preferred among
these. Suitable tin catalysts include stannous chloride, tin salts
of carboxylic acids such as dibutyltin dilaurate, as well as other
organometallic compounds such as are disclosed in U.S. Pat. No.
2,846,408 and elsewhere. A catalyst for the trimerization of
polyisocyanates, resulting in a polyisocyanurate, such as an alkali
metal alkoxide may also optionally be employed herein. Such
catalysts are used in an amount which measurably increases the rate
of polyurethane or polyisocyanurate formation.
[0559] In certain embodiments, where B-side mixtures of the present
invention comprise catalysts, the catalysts comprise tin based
materials. In certain embodiments, tin catalysts included in the
B-side mixtures are selected from the group consisting of: di-butyl
tin dilaurate, dibutylbis(laurylthio)stannate,
dibutyltinbis(isooctylmercapto acetate) and
dibutyltinbis(isooctylmaleate), tin octanoate and mixtures of any
two or more of these.
[0560] In certain embodiments, catalysts included in the B-side
mixtures comprise tertiary amines. In certain embodiments,
catalysts included in the B-side mixtures are selected from the
group consisting of: DABCO, pentametyldipropylenetriamine,
bis(dimethylamino ethyl ether), pentamethyldiethylenetriamine, DBU
phenol salt, dimethylcyclohexylamine,
2,4,6-tris(N,N-dimethylaminomethyl)phenol (DMT-30),
1,3,5-tris(3-dimethylaminopropyl)hexahydro-s-triazine, ammonium
salts and combinations or formulations of any of these.
[0561] Typical amounts of catalyst are 0.001 to 10 parts of
catalyst per 100 parts by weight of total polyol in the B-side
mixture. In certain embodiments, catalyst levels in the
formulation, when used, range between about 0.001 pph (weight parts
per hundred) and about 3 pph based on the amount of polyol present
in the B-side mixture. In certain embodiments, catalyst levels
range between about 0.05 pph and about 1 pph, or between about 0.1
pph and about 0.5 pph.
C. Blowing Agents
[0562] In certain embodiments, B-side mixtures of the present
invention contain blowing agents. Blowing agents may be chemical
blowing agents (typically molecules that react with A-side
components to liberate CO.sub.2 or other volatile compounds) or
they may be physical blowing agents (typically molecules with a low
boiling point that vaporize during the foam formation. Many blowing
agents are known in the art and may be applied to B-side
compositions of the present invention according to conventional
methodology. The choice of blowing agent and the amounts added can
be a matter of routine experimentation.
[0563] In certain embodiments, the blowing agent comprises a
chemical blowing agent. In certain embodiments, water is present as
a blowing agent. Water functions as a blowing agent by reacting
with a portion of the isocyanate in the A-side mixture to produce
carbon dioxide gas. Similarly, formic acid can be included as a
blowing agent. Formic acid functions as a blowing agent by reacting
with a portion of the isocyanate to produce carbon dioxide and
carbon monoxide gas.
[0564] In certain embodiments, water is present in an amount of
from 0.5 to 20 parts per 100 parts by weight of the polyol in the
B-side composition. In certain embodiments, water is present from
about 1 to 10 parts, from about 2 to 8 parts, or from about 4 to 6
parts per 100 parts by weight of polyol in the B-side composition.
In certain embodiments, it is advantageous not to exceed 2 parts of
water, not-to exceed 1.5 parts of water, or not to exceed 0.75
parts of water. In certain embodiments, it is advantageous to have
water absent.
[0565] In certain embodiments, formic acid is present in an amount
of from 0.5 to 20 parts per 100 parts by weight of the polyol in
the B-side composition. In certain embodiments, formic acid is
present from about 1 to 10 parts, from about 2 to 8 parts, or from
about 4 to 6 parts per 100 parts by weight of polyol in the B-side
composition.
[0566] In certain embodiments physical blowing agents can be used.
Suitable physical blowing agents include hydrocarbons,
fluorine-containing organic molecules hydrocarbons, chlorocarbons,
acetone, methyl formate and carbon dioxide. In some embodiments,
fluorine-containing organic molecules comprise perfluorinated
compounds, chlorofluorocarbons, hydrochlorofluorocarbons, and
hydrofluorocarbons. Suitable hydrofluoroalkanes are C.sub.1-4
compounds including difiuoromethane (R-32),
1.1,1,2-tetrafluoroethane (R-134a), 1,1-difluoroethane (R-152a),
difiuorochloroethane (R-142b), trifiuoromethane (R-23),
heptafluoropropane (R-227a), hexafluoropropane (R136),
1,1,1-trifluoroefhane (R-133), fluoroethane (R-161),
1,1,1,2,2-pentafluoropropane (R-245fa), pentafluoropropylene
(R2125a), 1,1,1,3-tetrafiuoropropane, tetrafhioropropylene
(R-2134a), 1,1,2,3,3-pentafluoropropane and
1,1,1,3,3-pentafiuoro-n-butane.
[0567] In certain embodiments, when a hydrofluorocarbon blowing
agent is present in the B-side mixture, it is selected from the
group consisting of: tetrafluoroethane (R-134a), pentafluoropropane
(R-245fa) and pentafluorobutane (R-365).
[0568] Suitable hydrocarbons for use as blowing agent include
nonhalogenated hydrocarbons such as butane, isobutane,
2,3-dimethylbutane, n- and i-pentane isomers, hexane isomers,
heptane isomers and cycloalkanes including cyclopentane,
cyclohexane and cycloheptane. Preferred hydrocarbons for use as
blowing agents include cyclopentane and notably n-pentane an
iso-pentane. In a certain embodiments the B-side composition
comprises a physical blowing agent selected from the group
consisting of tetrafluoroethane (R-134a), pentafluoropropane
(R-245fa), pentafluorobutane (R-365), cyclopentane, n-pentane and
iso-pentane.
[0569] In certain embodiments where a physical blowing agent is
present, it is used in an amount of from about 1 to about 20 parts
per 100 parts by weight of the polyol in the B-side composition. In
certain embodiments, the physical blowing agent is present from 2
to 15 parts, or from 4 to 10 parts per 100 parts by weight of the
polyol in the B-side composition.
D. Reactive Small Molecules
[0570] In certain embodiments, B-side mixtures of the present
invention include one or more small molecules reactive toward
isocyanates. In certain embodiments, reactive small molecules
included in the inventive B-side mixtures comprise organic
molecules having one or more functional groups selected from the
group consisting of alcohols, amines, carboxylic acids, thiols, and
combinations of any two or more of these. In some embodiments, a
non-polymeric small molecule has a molecular weight less than 1,000
g/mol, or less than 1,500 g/mol.
[0571] In certain embodiments, B-side mixtures of the present
invention include one or more alcohols. In certain embodiments, the
B-side mixtures include polyhydric alcohols.
[0572] In certain embodiments, reactive small molecules included in
the inventive B-side mixtures comprise dihydric alcohols. In
certain embodiments, the dihydric alcohol comprises a C.sub.2-40
diol. In certain embodiments, the dihydric alcohol is selected from
the group consisting of: 1,2-ethanediol, 1,2-propanediol,
1,3-propanediol, 1,2-butanediol, 1,3-butanediol, 1,4-butanediol,
1,5-pentanediol, 2,2-dimethylpropane-1,3-diol,
2-butyl-2-ethylpropane-1,3-diol, 2-methyl-2,4-pentane diol,
2-ethyl-1,3-hexane diol, 2-methyl-1,3-propane diol, 1,5-hexanediol,
1,6-hexanediol, 1,8-octanediol, 1,10-decanediol, 1,12-dodecanediol,
2,2,4,4-tetramethylcyclobutane-1,3-diol, 1,3-cyclopentanediol,
1,2-cyclohexanediol, 1,3-cyclohexanediol, 1,4-cyclohexanediol,
1,2-cyclohexanedimethanol, 1,3-cyclohexanedimethanol,
1,4-cyclohexanedimethanol, 1,4-cyclohexanediethanol, isosorbide,
glycerol monoesters, glycerol monoethers, trimethylolpropane
monoesters, trimethylolpropane monoethers, pentaerythritol
diesters, pentaerythritol diethers, and alkoxylated derivatives of
any of these.
[0573] In certain embodiments, a reactive small molecule included
in the inventive B-side mixtures comprises a dihydric alcohol
selected from the group consisting of: diethylene glycol,
triethylene glycol, tetraethylene glycol, higher poly(ethylene
glycol), such as those having number average molecular weights of
from 220 to about 2000 g/mol, dipropylene glycol, tripropylene
glycol, and higher poly(propylene glycols) such as those having
number average molecular weights of from 234 to about 2000
g/mol.
[0574] In certain embodiments, a reactive small molecule included
in the inventive B-side mixtures comprises an alkoxylated
derivative of a compound selected from the group consisting of: a
diacid, a diol, or a hydroxy acid. In certain embodiments, the
alkoxylated derivatives comprise ethoxylated or propoxylated
compounds.
[0575] In certain embodiments, a reactive small molecule included
in the inventive B-side mixtures comprises a polymeric diol. In
certain embodiments, a polymeric diol is selected from the group
consisting of polyethers, polyesters, hydroxy-terminated
polyolefins, polyether-copolyesters, polyether polycarbonates,
polycarbonate-copolyesters, and alkoxylated analogs of any of
these. In certain embodiments, the polymeric diol has an average
molecular weight less than about 2000 g/mol.
[0576] In some embodiments, a reactive small molecule included in
the inventive B-side mixtures comprises a triol or higher
polyhydric alcohol. In certain embodiments, a reactive small
molecule is selected from the group consisting of: glycerol,
1,2,4-butanetriol, 2-(hydroxymethyl)-1,3-propandiol; hexane triols,
trimethylol propane, trimethylol ethane, trimethylolhexane,
1,4-cyclohexanetrimethanol, pentaerythritol mono esters,
pentaerythritol mono ethers, and alkoxylated analogs of any of
these. In certain embodiments, alkoxylated derivatives comprise
ethoxylated or propoxylated compounds.
[0577] In some embodiments, a reactive small molecule comprises a
polyhydric alcohol with four to six hydroxy groups. In certain
embodiments, a coreactant comprises dipentaerithrotol or an
alkoxylated analog thereof. In certain embodiments, coreactant
comprises sorbitol or an alkoxylated analog thereof.
[0578] In certain embodiments, a reactive small molecule comprises
a hydroxy-carboxylic acid having the general formula
(HO).sub.xQ(COOH).sub.y, wherein Q is a straight or branched
hydrocarbon radical containing 1 to 12 carbon atoms, and x and y
are each integers from 1 to 3. In certain embodiments, a coreactant
comprises a diol carboxylic acid. In certain embodiments, a
coreactant comprises a bis(hydroxylalkyl) alkanoic acid. In certain
embodiments, a coreactant comprises a bis(hydroxylmethyl) alkanoic
acid. In certain embodiments the diol carboxylic acid is selected
from the group consisting of 2,2 bis-(hydroxymethyl)-propanoic acid
(dimethylolpropionic acid, DMPA) 2,2-bis(hydroxymethyl) butanoic
acid (dimethylolbutanoic acid; DMBA), dihydroxysuccinic acid
(tartaric acid), and 4,4'-bis(hydroxyphenyl) valeric acid. In
certain embodiments, a coreactant comprises an
N,N-bis(2-hydroxyalkyl)carboxylic acid.
[0579] In certain embodiments, a reactive small molecule comprises
a polyhydric alcohol comprising one or more amino groups. In
certain embodiments, a reactive small molecule comprises an amino
diol. In certain embodiments, a reactive small molecule comprises a
diol containing a tertiary amino group. In certain embodiments, an
amino diol is selected from the group consisting of: diethanolamine
(DEA), N-methyldiethanolamine (MDEA), N-ethyldiethanolamine (EDEA),
N-butyldiethanolamine (BDEA), N,N-bis(hydroxyethyl)-.alpha.-amino
pyridine, dipropanolamine, diisopropanolamine (DIPA),
N-methyldiisopropanolamine, Diisopropanol-p-toluidine,
N,N-Bis(hydroxyethyl)-3-chloroaniline,
3-diethylaminopropane-1,2-diol, 3-dimethylaminopropane-1,2-diol and
N-hydroxyethylpiperidine. In certain embodiments, a coreactant
comprises a diol containing a quaternary amino group. In certain
embodiments, a coreactant comprising a quaternary amino group is an
acid salt or quaternized derivative of any of the amino alcohols
described above.
[0580] In certain embodiments, a reactive small molecule is
selected from the group consisting of: inorganic or organic
polyamines having an average of about 2 or more primary and/or
secondary amine groups, polyalcohols, ureas, and combinations of
any two or more of these. In certain embodiments, a reactive small
molecule is selected from the group consisting of: diethylene
triamine (DETA), ethylene diamine (EDA), meta-xylylenediamine
(MXDA), aminoethyl ethanolamine (AEEA), 2-methyl pentane diamine,
and the like, and mixtures thereof. Also suitable for practice in
the present invention are propylene diamine, butylene diamine,
hexamethylene diamine, cyclohexylene diamine, phenylene diamine,
tolylene diamine, 3,3-dichlorobenzidene,
4,4'-methylene-bis-(2-chloroaniline), 3,3-dichloro-4,4-diamino
diphenylmethane, and sulfonated primary and/or secondary amines. In
certain embodiments, reactive small molecule is selected from the
group consisting of: hydrazine, substituted hydrazines, hydrazine
reaction products, and the like, and mixtures thereof. In certain
embodiments, a reactive small molecule is a polyalcohol including
those having from 2 to 12 carbon atoms, preferably from 2 to 8
carbon atoms, such as ethylene glycol, diethylene glycol, neopentyl
glycol, butanediols, hexanediol, and the like, and mixtures
thereof. Suitable ureas include urea and its derivatives, and the
like, and mixtures thereof.
[0581] In certain embodiments, reactive small molecules containing
at least one basic nitrogen atom are selected from the group
consisting of: mono-, bis- or polyalkoxylated aliphatic,
cycloaliphatic, aromatic or heterocyclic primary amines, N-methyl
diethanolamine, N-ethyl diethanolamine, N-propyl diethanolamine,
N-isopropyl diethanolamine, N-butyl diethanolamine, N-isobutyl
diethanolamine, N-oleyl diethanolamine, N-stearyl diethanolamine,
ethoxylated coconut oil fatty amine, N-allyl diethanolamine,
N-methyl diisopropanolamine, N-ethyl diisopropanolamine, N-propyl
diisopropanolamine, N-butyl diisopropanolamine, cyclohexyl
diisopropanolamine, N,N-diethoxylaniline, N,N-diethoxyl toluidine,
N,N-diethoxyl-1-aminopyridine, N,N'-diethoxyl piperazine,
dimethyl-bis-ethoxyl hydrazine,
N,N'-bis-(2-hydroxyethyl)-N,N'-diethylhexahydr op-phenylenediamine,
N-12-hydroxyethyl piperazine, polyalkoxylated amines, propoxylated
methyl diethanolamine, N-methyl-N,N-bis-3-aminopropylamine,
N-(3-aminopropyl)-N,N'-dimethyl ethylenediamine,
N-(3-aminopropyl)-N-methyl ethanolamine,
N,N'-bis-(3-aminopropyl)-N,N'-dimethyl ethylenediamine,
N,N'-bis-(3-aminopropyl)-piperazine, N-(2-aminoethyl)-piperazine,
N, N'-bisoxyethyl propylenediamine, 2,6-diaminopyridine,
diethanolaminoacetamide, diethanolamidopropionamide,
N,N-bisoxyethylphenyl thiosemicarbazide, N,N-bis-oxyethylmethyl
semicarbazide, p,p'-bis-aminomethyl dibenzyl methylamine,
2,6-diaminopyridine, 2-dimethylaminomethyl-2-methylpropanel,
3-diol. In certain embodiments, chain-extending agents are
compounds that contain two amino groups. In certain embodiments,
chain-extending agents are selected from the group consisting of:
ethylene diamine, 1,6-hexamethylene diamine, and
1,5-diamino-1-methyl-pentane.
E. Additives
[0582] In addition to the above components, A-side or B-side
mixtures of the present invention may optionally contain various
additives as are known in the art of polyurethane foam technology.
Such additives may include, but are not limited to compatibilizers,
colorants, surfactants, flame retardants, antistatic compounds,
antimicrobials, UV stabilizers, plasticizers, and cell openers.
[0583] Colorants
[0584] In certain embodiments, B-side mixtures of the present
invention comprise one or more suitable colorants. Many foam
products are color coded during manufacture to identify product
grade, to conceal yellowing, or to make a consumer product. The
historical method of coloring foam was to blend in traditional
pigments or dyes. Typical inorganic coloring agents included
titanium dioxide, iron oxides and chromium oxide. Organic pigments
originated from the azo/diazo dyes, phthalocyanines and dioxazines,
as well as carbon black. Typical problems encountered with these
colorants included high viscosity, abrasive tendencies, foam
instability, foam scorch, migrating color and a limited range of
available colors. Recent advances in the development of
polyol-bound colorants are described in: [0585] Miley, J. W.;
Moore, P. D. "Reactive Polymeric Colorants For Polyurethane",
Proceedings Of The SPI-26th Annual Technical Conference; Technomic:
Lancaster, Pa., 1981; 83-86. [0586] Moore, P. D.; Miley, J. W.;
Bates, S. H.; "New Uses For Highly Miscible Liquid Polymeric
Colorants In The Manufacture of Colored Urethane Systems";
Proceedings of the SPI-27th Annual Technical/Marketing Conference;
Technomic: Lancaster, Pa., 1982; 255-261. [0587] Bates, S. H.;
Miley, J. W. "Polyol-Bound Colorants Solve Polyurethane Color
Problems"; Proceedings Of The SPI-30th Annual Technical/Marketing
Conference; Technomic: Lancaster, Pa., 1986; 160-165 [0588] Vielee,
R. C.; Haney, T. V. "Polyurethanes"; In Coloring of Plastics;
Webber, T. G., Ed., Wiley-Interscience: New York, 1979,
191-204.
[0589] UV Stabilizers
[0590] In certain embodiments, B-side mixtures of the present
invention comprise one or more suitable UV stabilizers.
Polyurethanes based on aromatic isocyanates will typically turn
dark shades of yellow upon aging with exposure to light. A review
of polyurethane weathering phenomena is presented in: Davis, A.;
Sims, D. Weathering Of Polymers; Applied Science: London, 1983,
222-237. The yellowing is not a problem for most foam applications.
Light protection agents, such as hydroxybenzotriazoles, zinc
dibutyl thiocarbamate, 2,6-ditertiary butylcatechol,
hydroxybenzophenones, hindered amines and phosphites have been used
to improve the light stability of polyurethanes. Color pigments
have also been used successfully.
[0591] Flame Retardants
[0592] In certain embodiments, B-side mixtures of the present
invention comprise one or more suitable flame retardants.
Low-density, open-celled flexible polyurethane foams have a large
surface area and high permeability to air and thus will burn given
the application of sufficient ignition source and oxygen. Flame
retardants are often added to reduce this flammability. The choice
of flame retardant for any specific foam often depends upon the
intended service application of that foam and the attendant
flammability testing scenario governing that application. Aspects
of flammability that may be influenced by additives include the
initial ignitability, burning rate and smoke evolution.
[0593] The most widely used flame retardants are the chlorinated
phosphate esters, chlorinated paraffins and melamine powders. These
and many other compositions are available from specialty chemical
suppliers. A review of this subject has been given: Kuryla, W. C.;
Papa, A. J. Flame Retardancy of Polymeric Materials, Vol. 3; Marcel
Dekker: New York, 1975, 1-133.
[0594] Bacterlostats
[0595] Under certain conditions of warmth and high humidity,
polyurethane foams are susceptible to attack by microorganisms.
When this is a concern, additives against bacteria, yeast or fungi
are added to the foam during manufacture. In certain embodiments,
B-side mixtures of the present invention comprise one or more
suitable bacteriostats.
[0596] Plasticizers
[0597] In certain embodiments, B-side mixtures of the present
invention comprise one or more suitable plasticizers. Nonreactive
liquids have been used to soften a foam or to reduce viscosity for
improved processing. The softening effect can be compensated for by
using a polyol of lower equivalent weight, so that a higher
cross-linked polymer structure is obtained. These materials
increase foam density and often adversely affect physical
properties.
[0598] Cell-Openers
[0599] In certain embodiments, B-side mixtures of the present
invention comprise one or more suitable cell openers. In some
polyurethane foams it is necessary to add cell-openers to obtain
foam that does not shrink upon cooling. Known additives for
inducing cell-opening include silicone-based antifoamers, waxes,
finely divided solids, liquid perfluocarbons, paraffin oils,
long-chain fatty acids and certain polyether polyols made using
high concentrations of ethylene oxide.
[0600] Antistatic Agents
[0601] In certain embodiments, B-side mixtures of the present
invention comprise one or more suitable antistatic compounds. Some
flexible foams are used in packaging, clothing and other
applications where it is desired to minimize the electrical
resistance of the foam so that buildup of static electrical charges
is minimized. This has traditionally been accomplished through the
addition of ionizable metal salts, carboxylic acid salts, phosphate
esters and mixtures thereof. These agents function either by being
inherently conductive or by absorbing moisture from the air. The
desired net result is orders of magnitude reduction in foam surface
resistivity.
[0602] Compatibilizers
[0603] In certain embodiments, B-side mixtures of the present
invention comprise one or more suitable compatibilizers.
Compatibilizers are molecules that allow two or more nonmiscible
ingredients to come together and give a homogeneous liquid phase.
Many such molecules are known to the polyurethane industry, these
include: amides, amines, hydrocarbon oils, phthalates,
polybutyleneglycols, and ureas.
Certain Embodiments
[0604] In certain embodiments, the present invention can be
described as in the following clauses. [0605] 1. A method for
increasing the load bearing properties of a polyurethane foam
composition, the foam composition comprising the reaction product
of a polyol component and a polyisocyanate component, the method
comprising the step of incorporating into the polyol component a
polycarbonate polyol derived from the copolymerization of one or
more epoxides and carbon dioxide, wherein the polycarbonate polyol
is added in a quantity from about 2 weight percent to about 50
weight percent of all polyols present in the polyol component.
[0606] 2. The method of clause 1, wherein the polyol component
comprises one or more polyols selected from the group consisting of
polyether polyols, polyester polyols, aliphatic polyols, and
mixtures of any two or more of these. [0607] 3. The method of
clause 1, wherein the polyol component substantially comprises
polyether polyol. [0608] 4. The method of clause 1, wherein the
polycarbonate polyol is added in a quantity from about 5 weight
percent, to about 25 weight percent of all polyol present in the
polyol component. [0609] 5. The method of clause 4, wherein the
polycarbonate polyol is added in a quantity from about 2 weight
percent to about 10 weight percent of all polyol present in the
polyol component. [0610] 6. The method of clause 4, wherein the
polycarbonate polyol is added in a quantity from about 10 weight
percent, to about 20 weight percent of all polyol present in the
polyol component. [0611] 7. The method of clause 4, wherein the
polycarbonate polyol is added in a quantity from about 20 weight
percent, to about 30 weight percent of all polyol present in the
polyol component. [0612] 8. The method of clause 4, wherein the
polycarbonate polyol is added in a quantity from about 30 weight
percent, to about 50 weight percent of all polyol present in the
polyol component. [0613] 9. The method of clause 1, wherein a
compression force deflection (CFD) value measured according to ASTM
D3574 of the foam composition comprising the added polycarbonate
polyol is greater than the CFD value of the corresponding foam
composition lacking the added polycarbonate polyol. [0614] 10. The
method of clause 9, wherein the CFD value of the foam composition
comprising the added polycarbonate polyol is at least 10%, at least
20%, at least 30%, at least 40% or at least 50% greater than the
CFD value of the corresponding foam composition lacking the added
polycarbonate polyol. [0615] 11. The method of clause 10, wherein
the CFD value of the foam comprising the added polycarbonate polyol
is at least 20%, at least 30%, at least 40% or at least 50% greater
than the CFD value of the corresponding foam without the added
polycarbonate polyol. [0616] 12. The method of any one of clauses
9-11, wherein the CFD values are normalized for density of the foam
compositions being compared. [0617] 13. The method of any one of
clauses 9-11, wherein the foam compositions are formulated such
that the foam composition comprising the added polycarbonate polyol
and the corresponding foam composition lacking the added
polycarbonate polyol have substantially the same density. [0618]
14. The method of clause 1, wherein the foam composition comprises
flexible polyurethane foam. [0619] 15. The method of clause 1,
wherein the foam composition comprises viscoelastic polyurethane
foam. [0620] 16. The method of clause 1, wherein the foam
composition comprises rigid polyurethane foam. [0621] 17. The
method of clause 1, wherein the density measured according to ASTM
D3574 of the foam composition comprising the added polycarbonate
polyol is less than the density of the corresponding foam
composition lacking the added polycarbonate polyol, and wherein a
compression force deflection (CFD) value measured according to ASTM
D3574 of the foam composition comprising the added polycarbonate
polyol is greater than the CFD value of the corresponding foam
composition lacking the added polycarbonate polyol. [0622] 18. The
method of clause 18, wherein the density of the foam composition
comprising the added polycarbonate polyol is at least 10% less than
the density of the corresponding foam composition lacking the added
polycarbonate polyol. [0623] 19. The method of clause 18, wherein
the density of the foam with the added polycarbonate polyol is at
least 20% less than the density of the corresponding foam without
the added polycarbonate polyol. [0624] 20. The method of clause 19,
wherein the density of the foam with the added polycarbonate polyol
is at least 25%, at least 30%, at least 40% or at least 50% greater
than the CFD value of the corresponding foam without the added
polycarbonate polyol. [0625] 21. The method of any of clauses
17-19, wherein the CFD value of the foam composition comprising the
added polycarbonate polyol is at least 10% greater than the CFD
value of the corresponding foam composition lacking the added
polycarbonate polyol. [0626] 22. The method of clause 21, wherein
the CFD value of the foam comprising the added polycarbonate polyol
is at least 20%, at least 30%, at least 40% or at least 50% greater
than the CFD value of the corresponding foam without the added
polycarbonate polyol. [0627] 23. The method of clause 1, wherein
the polycarbonate polyol contains a primary repeating unit having a
structure:
[0627] ##STR00138## [0628] where R.sup.1, R.sup.2, R.sup.3, and
R.sup.4 are, at each occurrence in the polymer chain, independently
selected from the group consisting of --H, fluorine, an optionally
substituted C.sub.1-40 aliphatic group, an optionally substituted
C.sub.1-20 heteroaliphatic group, and an optionally substituted
aryl group, where any two or more of R.sup.1, R.sup.2, R.sup.3, and
R.sup.4 may optionally be taken together with intervening atoms to
form one or more optionally substituted rings optionally containing
one or more heteroatoms. [0629] 24. The method of clause 23,
wherein the polycarbonate polyol contains a primary repeating unit
having a structure:
[0629] ##STR00139## [0630] 25. The method of clause 24, wherein
R.sup.1 is, at each occurrence in the polymer chain, independently
--H, or --CH.sub.3. [0631] 26. The method of clause 25, wherein the
polycarbonate polyol is characterized in that it has an Mn between
about 500 g/mol and about 20,000 g/mol. [0632] 27. The method of
clause 26, wherein the polycarbonate polyol is characterized in
that it has an Mn between about 1,000 g/mol and about 5,000 g/mol.
[0633] 28. The method of clause 26, wherein the polycarbonate
polyol is characterized in that it has an Mn between about 1,000
g/mol and about 3,000 g/mol. [0634] 29. The method of clause 28,
wherein the polycarbonate polyol is characterized in that it has an
Mn of about 1,000 g/mol, about 1,200 g/mol, about 1,500 g/mol,
about 2,000 g/mol, about 2.500 g/mol or about 3,000 g/mol. [0635]
30. The method of clause 25, wherein the aliphatic polycarbonate
polyol is characterized in that more than 98%/a, more than 99%, or
more than 99.5% of the chain ends are groups reactive toward
isocyanate. [0636] 31. The method of clause 25, wherein the chain
ends reactive toward isocyanate comprise --OH groups. [0637] 32. A
polyurethane foam composition comprising the reaction product of a
polyol component and a polyisocyanate component, wherein the polyol
component comprises a polycarbonate polyol derived from the
copolymerization of one or more epoxides and carbon dioxide,
wherein the polycarbonate polyol is present in a quantity from
about 2 weight percent to about 50 weight percent of all polyols
present in the polyol component and characterized in that a
compression force deflection (CFD) value measured according to ASTM
D3574 of the foam composition comprising the added polycarbonate
polyol is greater than the CFD value of a corresponding foam
composition lacking the polycarbonate polyol. [0638] 33. The
polyurethane foam composition of clause 32, wherein the polyol
component comprises one or more polyols selected from the group
consisting of polyether polyols, polyester polyols, aliphatic
polyols, and mixtures of any two or more of these. [0639] 34. The
polyurethane foam composition of clause 32, wherein the polyol
component substantially comprises polyether polyol. [0640] 35. The
polyurethane foam composition of clause 32, wherein the
polycarbonate polyol is present in a quantity from about 5 weight
percent, to about 25 weight percent of all polyol present in the
polyol component. [0641] 36. The polyurethane foam composition of
clause 32, wherein the polycarbonate polyol is present in a
quantity from about 2 weight percent to about 10 weight percent of
all polyol present in the polyol component. [0642] 37. The
polyurethane foam composition of clause 32, wherein the
polycarbonate polyol is present in a quantity from about 10 weight
percent, to about 20 weight percent of all polyol present in the
polyol component. [0643] 38. The polyurethane foam composition of
clause 32, wherein the polycarbonate polyol is present in a
quantity from about 20 weight percent, to about 30 weight percent
of all polyol present in the polyol component. [0644] 39. The
polyurethane foam composition of clause 32, wherein the
polycarbonate polyol is present in a quantity from about 30 weight
percent, to about 50 weight percent of all polyol present in the
polyol component. [0645] 40. The polyurethane foam composition of
clause 32, wherein the CFD value of the foam composition comprising
the polycarbonate polyol is at least 10% greater than the CFD value
of the corresponding foam composition lacking the polycarbonate
polyol. [0646] 41. The polyurethane foam composition of clause 40,
wherein the CFD value of the foam with the polycarbonate polyol is
at least 20%, at least 30%, at least 40% or at least 50% greater
than the CFD value of the corresponding foam without the
polycarbonate polyol. [0647] 42. The polyurethane foam composition
of clause 40 or 41, wherein the CFD values are normalized for
density of the foam compositions being compared. [0648] 43. The
polyurethane foam composition of clause 40 or 41, wherein the foam
composition is formulated such that the foam composition comprising
the added polycarbonate polyol and the corresponding foam
composition lacking the added polycarbonate polyol have
substantially the same density. [0649] 44. The polyurethane foam
composition of clause 32, wherein the foam composition comprises
flexible polyurethane foam. [0650] 45. The polyurethane foam
composition of clause 32, wherein the foam composition comprises
viscoelastic polyurethane foam. [0651] 46. The polyurethane foam
composition of clause 32, wherein the foam composition comprises
rigid polyurethane foam. [0652] 47. The polyurethane foam
composition of clause 32, wherein the density measured according to
ASTM D3574 of the foam composition comprising the polycarbonate
polyol is less than the density of the corresponding foam
composition lacking the polycarbonate polyol. [0653] 48. The
polyurethane foam composition of clause 47, wherein the density of
the foam comprising the polycarbonate polyol is at least 10% less
than the density of the corresponding foam composition lacking the
added polycarbonate polyol. [0654] 49. The polyurethane foam
composition of clause 47, wherein the density of the foam with the
added polycarbonate polyol is at least 20%, at least 30%, at least
40% or at least 50% greater than the CFD value of the corresponding
foam composition without the added polycarbonate polyol. [0655] 50.
The polyurethane foam composition of any of clauses 47-49, wherein
the measured CFD value is at least 10% greater than the CFD value
of the corresponding foam composition lacking the polycarbonate
polyol. [0656] 51. The polyurethane foam composition of clause 50,
wherein the CFD value of the foam with the polycarbonate polyol is
at least 20%, at least 30%, at least 40% or at least 50% greater
than the CFD value of the corresponding foam without the added
polycarbonate polyol. [0657] 52. The polyurethane foam composition
of clause 32, wherein the polycarbonate polyol contains a primary
repeating unit having a structure:
[0657] ##STR00140## [0658] where R.sup.1, R.sup.2, R.sup.3, and
R.sup.4 are, at each occurrence in the polymer chain, independently
selected from the group consisting of --H, fluorine, an optionally
substituted C.sub.1-40 aliphatic group, an optionally substituted
C.sub.1-20 heteroaliphatic group, and an optionally substituted
aryl group, where any two or more of R.sup.1, R.sup.2, R.sup.3, and
R.sup.4 may optionally be taken together with intervening atoms to
form one or more optionally substituted rings optionally containing
one or more heteroatoms. [0659] 53. The polyurethane foam
composition of clause 32, wherein the polycarbonate polyol contains
a primary repeating unit having a structure:
[0659] ##STR00141## [0660] 54. The polyurethane foam composition of
clause 32, wherein R.sup.1 is, at each occurrence in the polymer
chain, independently --H, or --CH.sub.3. [0661] 55. The
polyurethane foam composition of clause 54, wherein the
polycarbonate polyol is characterized in that it has an Mn between
about 500 g/mol and about 20,000 g/mol. [0662] 56. The polyurethane
foam composition of clause 55, wherein the polycarbonate polyol is
characterized in that it has an Mn between about 1,000 g/mol and
about 5,000 g/mol. [0663] 57. The polyurethane foam composition of
clause 55, wherein the polycarbonate polyol is characterized in
that it has an Mn between about 1,000 g/mol and about 3,000 g/mol.
[0664] 58. The polyurethane foam composition of clause 55, wherein
the polycarbonate polyol is characterized in that it has an Mn of
about 1,000 g/mol, about 1,200 g/mol, about 1,500 g/mol, about
2,000 g/mol, about 2,500 g/mol or about 3,000 g/mol. [0665] 59. The
polyurethane foam composition of clause 55, wherein the
polycarbonate polyol is characterized in that more than 98%, more
than 99%, or more than 99.5% of the chain ends are groups reactive
toward isocyanate. [0666] 60. The polyurethane foam composition of
clause 59, wherein the chain ends reactive toward isocyanate
comprise --OH groups. [0667] 61. A seating foam comprising the
reaction product between an isocyanate component and a polyol
component wherein the polyol component comprises from about 5
weight percent to about 20 weight percent of a polycarbonate polyol
having a primary repeating unit with the structure:
[0667] ##STR00142## [0668] wherein, [0669] R.sup.1 is, at each
occurrence in the polymer chain, independently --H, or --CH.sub.3;
[0670] the polycarbonate polyol has an Mn between about 1,000 g/mol
and about 5.000 g/mol; and [0671] the polycarbonate polyol is
characterized in that more than 99% of the chain ends are groups
reactive toward isocyanate. [0672] 62. A viscoelastic foam article
comprising the reaction product between an isocyanate component and
a polyol component wherein the polyol component comprises from
about 5 weight percent to about 20 weight percent of a
polycarbonate polyol having a primary repeating unit with the
structure:
[0672] ##STR00143## [0673] wherein, [0674] R.sup.1 is, at each
occurrence in the polymer chain, independently --H, or --CH.sub.3;
[0675] the polycarbonate polyol has an Mn between about 1,000 g/mol
and about 5,000 g/mol; and [0676] the polycarbonate polyol is
characterized in that more than 99% of the chain ends are groups
reactive toward isocyanate.
* * * * *